Hybrid solar panel mounting assembly with a tilted ledge

ABSTRACT

A trim-rail for use in a solar panel mounting assembly is disclosed. The trim-rail includes a tilted spring support ledge on a side of the trim-rail. A photovoltaic module is elastically supportable on the tilted spring support ledge when the photovoltaic module is installed on the tilted spring support ledge.

This application is a continuation-in-part of application Ser. No.15/138,030 filed Apr. 25, 2016, which claims the benefit of U.S.Provisional Application No. 62/200,262, filed Aug. 3, 2015, and U.S.Provisional Application No. 62/217,580, filed Sep. 11, 2015, thedisclosures of which are expressly incorporated by reference herein.

BACKGROUND OF THE INVENTION

The solar industry is growing world-wide and, as a result,more-efficient structures are desirable for mounting photovoltaicmodules to a structure, such as a roof of a home or other building.Whereas many different structures are known, there is a desire to reducethe complexity of such structures, and improve the efficiency of suchstructures.

Therefore, there is a need for an improved apparatus for mountingphotovoltaic modules.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a first embodiment of a trim-rail assembly inaccordance with the principles of the present invention;

FIG. 2 illustrates a trim-rail of the trim-rail assembly of FIG. 1;

FIG. 3 illustrates a splice of the trim-rail assembly of FIG. 1;

FIG. 4 illustrates a connector of the trim-rail assembly of FIG. 1;

FIG. 5 illustrates a second embodiment of a trim-rail assembly inaccordance with the principles of the present invention;

FIG. 6 is a perspective view of the system for removably and adjustablymounting a device on a surface in an operative environment as anapparatus for removably and adjustably mounting one or more photovoltaicmodules on a surface such as a roof as shown;

FIG. 7 is a top view of a module installed on a surface;

FIG. 8 is a perspective view of a rail in accordance with the presentinvention;

FIG. 9 is an end view of a rail in accordance with the presentinvention;

FIG. 10 is a top view of a rail in accordance with the presentinvention;

FIG. 11 is a side view of a rail in accordance with the presentinvention;

FIG. 12 shows additional end views of a rail in accordance with thepresent invention;

FIG. 13 shows a front view of clamps in accordance with the presentinvention;

FIG. 14 shows a blown up view of the fin of a clamp as noted in FIG. 13;

FIG. 15 is a perspective view of one embodiment of the clamp;

FIG. 16 is a perspective view of yet another embodiment of the clamp;

FIG. 17 is a perspective view of the apparatus and method forpositioning a module on an object in an operative environment;

FIG. 18 is a perspective view of the triple track rail in accordancewith the present invention;

FIG. 19A is a side view of the triple track rail;

FIG. 19B is an end view of the triple track rail;

FIG. 20 is a perspective view of the connector bracket in accordancewith the present invention;

FIG. 21 is a top partially cut away view of a module;

FIG. 22 of the drawing is a perspective view of a mounting systemlocated on a roof;

FIG. 23 is a perspective view of a first embodiment of the low profilemounting system in an operative environment;

FIG. 24 is an exploded end view of the first embodiment of the firstembodiment of the low profile mounting system;

FIG. 25 is a perspective view of a second embodiment of the low profilemounting system in an operative environment;

FIG. 26 is an exploded end view of a second embodiment of the lowprofile mounting system;

FIG. 27 is a perspective view of a third embodiment of the low profilemounting system in an operative environment;

FIG. 28 is an exploded end view of the third embodiment of the lowprofile mounting system;

FIG. 29 is a perspective view of a fourth embodiment of the low profilemounting system in an operative environment;

FIG. 30 is an exploded end view of the fourth embodiment of the lowprofile mounting system;

FIG. 31 is a perspective view of a fifth embodiment of the low profilemounting system in an operative environment;

FIG. 32 is an exploded end view of the fifth embodiment of the lowprofile mounting system;

FIG. 33 is a perspective view of a sixth embodiment of the low profilemounting system in an operative environment;

FIG. 34 is an exploded end view of the sixth embodiment of the lowprofile mounting system;

FIG. 35A is a cross-section of an apparatus for mounting photovoltaicmodules with a mounted photovoltaic module in accordance with anembodiment of the present invention;

FIG. 35B is a perspective view of a bonding clip in accordance with anembodiment of the present invention;

FIG. 35C is a cross-section of the bonding clip of FIG. 35B aspositioned with respect to the bracket of the apparatus and aphotovoltaic module;

FIG. 36 is a side view of the apparatus for mounting photovoltaicmodules of FIG. 35A with two adjacent photovoltaic modules mounted inthe apparatus;

FIG. 37 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 35A in a first position of the footer with respect tothe bracket;

FIG. 38 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 35A in a second position of the footer with respect tothe bracket;

FIG. 39 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 35A in a third position of the footer with respect tothe bracket;

FIG. 40 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 37 in the first position of the footer with respect tothe bracket and the footer attached to a roof support;

FIG. 41 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 38 in the second position of the footer with respect tothe bracket and the footer attached to a roof support;

FIG. 42 is a perspective view of the apparatus for mounting photovoltaicmodules of FIG. 39 in the third position of the footer with respect tothe bracket and the footer attached to a roof support;

FIG. 43 is a perspective view of a second embodiment of an apparatus formounting photovoltaic modules in accordance with the principles of thepresent invention;

FIG. 44 is a top view of the apparatuses of FIGS. 35A and 43 as used tomount photovoltaic modules;

FIG. 45 is a perspective view of a trim in accordance with theprinciples of the present invention;

FIG. 46 is a perspective view of a trim mounting bracket in accordancewith the principles of the present invention;

FIG. 47 is a perspective view of the trim mounting bracket of FIG. 46 assecured to the bracket of the mounting apparatus;

FIG. 48 is a side view of the trim mounting bracket and trim as securedto the bracket of the mounting apparatus;

FIG. 49 is a perspective view of a micro-inverter mounting bracket inaccordance with the principles of the present invention;

FIG. 50 is a side view of the micro-inverter mounting bracket as securedto the bracket of the mounting apparatus and with a micro-inverter;

FIG. 51 illustrates a known configuration of a rail-less ornon-rail-based system; and

FIGS. 52-59 disclose various configurations for the components of thehybrid solar panel mounting assembly of the present invention.

FIGS. 60-61 are perspective views of an embodiment of a heightadjustable solar panel mounting assembly in accordance with theprinciples of the present invention;

FIG. 62 is a side view of the assembly of FIGS. 60-61;

FIG. 63 is a side view of a second embodiment of a trim-rail of thetrim-rail assembly in accordance with the principles of the presentinvention;

FIG. 64 is a side view of a second embodiment of a splice of thetrim-rail assembly in accordance with the principles of the presentinvention;

FIG. 65 is a side view of the second embodiment of the trim-rail and afooter assembly according to the principles of the present invention;

FIG. 66 is a perspective view of the footer assembly of FIG. 65;

FIG. 67 is a perspective view of an apparatus for mounting photovoltaicmodules according to another embodiment of the present invention;

FIG. 68 is a perspective view of the embodiment of FIG. 67;

FIG. 69 is a perspective view an apparatus for mounting photovoltaicmodules according to another embodiment of the present invention;

FIG. 70 is a side view an apparatus for mounting photovoltaic modulesaccording to another embodiment of the present invention;

FIG. 71 is an isometric view of the embodiment of FIG. 70;

FIG. 72 is a perspective view of a drive in accordance with theprinciples of the present invention;

FIG. 73 is another perspective view of the drive of FIG. 72;

FIG. 74 is a side view of the drive of FIGS. 72 and 73;

FIG. 75 is a side view of another embodiment of a drive in accordancewith the principles of the present invention;

FIG. 76 is a cross-sectional view of the drive of FIG. 75;

FIG. 77 is a perspective view of an apparatus for mounting photovoltaicmodules according to another embodiment of the present invention;

FIG. 78 is a perspective view of an embodiment of a trim-rail with atilted ledge in accordance with the principles of present invention;

FIG. 79 is a right end view of the embodiment of the trim-rail with atilted ledge of FIG. 78;

FIG. 80 is a front view of the embodiment of the trim-rail with a tiltedledge of FIG. 78;

FIG. 81 is a rear view of the embodiment of the trim-rail with a tiltedledge of FIG. 78;

FIG. 82 is a top view of the embodiment of the trim-rail with a tiltedledge of FIG. 78;

FIG. 83 is a bottom view of the embodiment of the trim-rail with atilted ledge of FIG. 78; and

FIGS. 84A and 84B are right end views of an embodiment of a solar panelmounting assembly with the trim-rail with a tilted ledge of FIG. 78.

DETAILED DESCRIPTION OF THE DRAWINGS

Briefly, the present invention, amongst other features, provides ahybrid assembly for removably and adjustably mounting solar panels on asurface.

Before particularly discussing the hybrid assembly itself, components ofthe hybrid assembly will first be discussed. Generally, the hybridassembly consists of components of a “rail-based” system and componentsof a “rail-less” or “non-rail based” system.

A rail-based system generally includes at least one rail that extends anentire length or width of at least one solar panel of a plurality ofsolar panels that are utilized in a solar panel array. The rail mountsthe solar panel(s) to a surface, such as the roof of a home or building.The rail may also be referred to as a continuous mounting beam. As willbe further discussed below, such rails may be either a trim-rail, asingle rail, or a shared rail. However, the present invention is notlimited to these particular types of rails.

A rail-less or non-rail-based system generally includes a component thatdoes not extend the entire length or width of a solar panel, but rather,is a mounting structure that only attaches to a discrete portion of asolar panel, or discrete portions of adjacent solar panels, for example,at the adjacent corners of four adjacent solar panels arranged in a 2 by2 orientation with two adjacent solar panels in a first row and twoadjacent solar panels in a second row directly above or below the firstrow. Such a component may also be referred to as a micro-rail. A shortmicro-rail only attaches to a discrete portion of a solar panel, or todiscrete portions of at-most two adjacent solar panels.

Thus, in a rail-less or non-rail-based system, each component that cansupport a solar panel connects together only immediate next-doorneighbor solar panels. As described above and as will be furtherdescribed below, these immediate next-door neighbor solar panels are amaximum of four when a micro-rail is used, and three in an installationwhere the micro-rail is used around an obstacle in the mounting surface,and two when a short micro-rail is used.

In contrast, in a rail-based system, the component that can support asolar panel, i.e., the rail, can also connect together remote panels.Remote panels are not immediate next-door neighbors to each of theconnected panels. Thus, connected remote panels have one or moreintermediate panels separating them.

As will be further discussed below, utilizing a rail-based systemcomponent, e.g., a rail, in the front row of a solar panel arrayprovides a benchmark or baseline to construct the remaining solar arraywith the modules being in a more stable position and it is easier toalign and square the array and the modules. Also, having the first(lower-most) structure mounted to the roof being a structurally stiffand strong piece of racking (i.e., a rail, which may be a trim-rail),makes it safer for the installer to stand on a steeply pitched roof.

By also using rail-less or non-rail-based system components in the restof the array, this allows the installer the flexibility to work aroundobstructions, e.g., vents, skylights, etc., without needing tocut/modify a rail. This also allows for mixing of the orientation of thesolar panel modules within a row.

Thus, in the hybrid solar panel mounting assembly of the presentinvention, a combination of rail-based system components and rail-lesssystem components are used to mount a plurality of solar panels in asolar panel array to a surface.

Below is provided exemplary embodiments of components of rail-basedsystems and non-rail-based systems that may be utilized in the hybridsolar panel mounting system of the present invention. However, thepresent invention is not limited to these particular embodiments ofcomponents of rail-based systems and non-rail-based systems.

Rail-Based System Components

Trim-Rail Assembly

FIG. 1 illustrates a trim-rail assembly 10 in accordance with theprinciples of the present invention. The trim-rail assembly 10 includesa trim-rail 100, a splice 200, a connector 300, a mounting bracket, orfooter, 400, and a track 500.

The trim-rail 100 can be further seen in FIG. 2. Trim-rail 100 includesboth a rail 110 and a trim 120, where the rail 110 and trim 120 areintegrated as a single, monolithic structure. Thus, the trim-rail 100includes a rail 110 that extends an entire length or width of at leastone solar panel of a plurality of solar panels that are utilized in asolar panel array. The rail 110 of the trim-rail 100 mounts the solarpanel(s) to a surface, such as the roof of a home or building. Since therail 110 extends the entire length or width of at least one solar panelof a plurality of solar panels that are utilized in a solar panel array,so does the trim 120. Rail 110 can have an “I-beam” shape incross-section.

In FIG. 2, trim 120 has a generally curved surface which extendsdownwardly and outwardly from the top of the trim-rail 100 to a lowerportion of the trim-rail 100 and then downwardly to a lowest-mostportion of the trim-rail 100. Trim-rail 100 can be an extruded product.

Thus, in FIG. 2, the trim 120 can provide for an aesthetically-pleasingfront surface for the trim-rail 100 when the trim-rail 100 is used asthe front-most rail in the hybrid solar panel mounting assembly of thepresent invention. Additionally, the trim-rail 100 can also assist inproviding for a fire protection mechanism by further restricting theflow of air under the trim-rail 100, and thus under the photovoltaicmodule(s) that are mounted on the trim-rail 100.

Thus, in FIG. 2, because the rail 110 and the trim 120 of the trim-rail100 are a single, monolithic integrated structure, there is no need tomount the trim 120 on a separate rail. The integrated structure of thetrim-rail 100 provides for both mounting a solar panel(s) to a surfaceby the rail 110 and providing a trim 120 for the rail. Further yetbecause the trim 120 and the rail 110 are a single integrated structure,the trim 120 is part the rigid structure of the trim-rail 100, and thus,it is also a rigid structure itself. As such, the trim 120 also directlysupports the solar panel modules. In some embodiments, the wallthickness of trim 120 can be the same as the wall thickness of rail 110.

In FIG. 2, the rail 110 includes a first track 112A and a second track112B at a bottom of the rail 110. The bottom of the rail is the portionof the rail that is closest to the mounting surface. As will be furtherdiscussed below, the tracks 112A, 112B are able to receive within themmounting hardware that is used to mount the rail 110, and thus trim-rail100, on the footer 400. The tracks are provided on both sides of therail 110 so that the footer 400 may be mounted on either side of therail 110.

In FIG. 2, a vertical wall 114, i.e., vertical with respect to thesurface on which the trim-rail 100 is mounted, is provided extendingfrom the bottom of the rail 110. Extending perpendicularly from thevertical wall 114 are lower ledge 114A and upper ledge 114B. Lower ledge114A extends further from wall 114 than upper ledge 114B. An edge of asolar panel(s) that is mounted on trim-rail 100 is positioned ontrim-rail 100 between ledges 114A, 114B. The bottom of the solar panelis supported on lower ledge 114A and the top of the solar panel isdisposed under, and in engagement with, upper ledge 114B. Thus, the edgeof the solar panel is secured on trim-rail 100 between lower ledge 114Aand upper edge 114B of rail 110.

In FIG. 2, trim-rail 100 also defines a hollow chamber 116 which isbounded by trim 120, vertical wall 114, and a bottom wall 116A.

FIG. 3 further illustrates an embodiment of splice 200. Splice 200 isused to splice together two adjacent trim-rails 100. As can beunderstood, and as can be seen in FIG. 1, a first end of the splice 200is received within hollow chamber 116 of a first adjacent trim-rail 100.A second end of the splice 200 would be received within a hollow chamber116 of a second adjacent trim-rail 100. Thus, the splice 200 rigidlyjoins a first trim-rail to a second adjacent trim-rail.

In FIG. 3, the splice 200 has a structure that is complementary to thetrim-rail 100. Thus, the splice 200 has a trim-like portion 200A thathas a contour that is complementary to trim 120 of trim-rail 100. Thus,when splice 200 is received within hollow chamber 116 of a trim-rail100, the trim-like portion 200A of splice 200 generally engages with theinside wall of trim 120 of trim-rail 100.

Similarly, in FIG. 3, the splice 200 has a vertical wall 200B. Thus,when splice 200 is received within hollow chamber 116 of a trim-rail100, the vertical wall 200B of splice 200 generally engages with theinside wall of vertical wall 114 of trim-rail 100.

Thus, in FIG. 3, the splice 200 is firmly engaged within respectivehollow chambers 116 of adjacent trim-rails 100.

Although not required, in FIG. 4, splice 200 can be further securedwithin the adjacent trim-rails 100 by use of respective connector 300.As such, splice 200 also has a structure 210 that receives within it aportion of connector 300, which can also be further seen in FIG. 4.Structure 210 includes slot 211. Connector 300 includes two straps 301Aand 301B. The two straps 301A and 301B are bent such that they arereceived with slot 211 and engage into splice 200 to secure connector300 on splice 200.

In FIG. 2, trim-rail 100 also includes upper flange 118A and lowerflange 118B on vertical wall 114 and connector 300 includes an upperstrap 302A and a lower strap 302B. Upper strap 302A engages with upperflange 118A to prevent the connector 300 from being slipped any furtherinto trim-rail 100. Lower strap 302B then engages with the outer edge ofwall 114 and lower flange 118B.

In FIG. 1, at least portions of connector 300 engage into both trim-rail100 and splice 200 to electrically bond the trim-rail 100 to the splice200. These portions can be the respective straps 301A, 301B.

As mentioned above, FIG. 1 shows an embodiment of footer 400 and track500. The footer 400 is variably positionable on the trim-rail 100 alongeither slot 112A or 112B. The footer 400 is generally L-shaped with afirst, upright leg 401 and a second, flat leg 402. The upright leg 401is “upright” in the sense that it extends perpendicularly to the surfaceon which the footer 400 is mounted. The flat leg 402 is “flat” in thesense that it extends parallel to the surface on which the footer 400 ismounted. The upright leg 401 contains at least one aperture, throughwhich a securement mechanism, which may be a bolt and a nut, extends. Asshown in FIG. 1, two, or more, apertures may be provided, such that theposition of the trim-rail 100 with respect to the upright leg 401 of thefooter 400 may be adjusted by use of the securement mechanism in thedifferent apertures. The shaft of the bolt extends through an apertureof the upright leg 401 and the nut, or other structure, of thesecurement mechanism is disposed within the slot 112A of trim-rail 100,or slot 112B if the footer 400 is placed on the opposing side of thetrim-rail 100. As the bolt is threaded down on the nut, the footer 400is secured at a position on the trim-rail 100 along the slot 112A. Theflat leg 402 of the footer also contains an aperture, and an additionalsecurement mechanism, which may be a lag bolt, extends through theaperture and into a slot 501 of the track 500, in the same manner asdiscussed above with respect to the slot of the trim-rail 100, such thatthe footer 400 is also variably positionable on the track 500 along theslot 501 of the track.

Thus, as discussed above in FIG. 1, the footer 400 is variablypositionable on both the trim-rail 100 along a slot, and the track 500along a slot, via the respective securement mechanisms that are disposedthrough the footer 400 and are received in the respective slots. Byloosening the nuts on the bolts, while the nuts remain in the slots, thefooter and securement mechanisms may be moved and positioned anywherealong the longitudinal length of the trim-rail and the track, and thentightened to secure the footer 400 on the trim-rail 100 and track 500 ata desired positioned. This provides a benefit since, as will be furtherdiscussed later in this specification, the footer is not constrained toa single position on the trim-rail or track, but rather, it can bevariably positioned on the trim-rail and track.

FIG. 5 provides another embodiment for the trim-rail assembly 10 of thepresent invention. This embodiment also includes a trim-rail 100, splice200, connector 300, and track 500, as in the embodiment of FIG. 1.

As can be seen in FIG. 5, the footer 400 has a different configuration.Footer 400 of the embodiment of FIG. 5 includes slots 410 that mate witha tab(s) 119 in the trim-rail 100 in a tongue-and-groove type matingconfiguration. The horizontal slots are positioned one above the othervertically on the footer and may extend the entire length of the uprightleg. As such, the vertical position of the trim-rail 100 with respect tothe footer 400 can be variably adjusted by engaging the tab 119 of thetrim-rail 100 in different slots 410 of the footer 400. Further, themating of the slots and the tab(s) can provide for a stronger structuralconnection between the footer and the trim-rail. As discussed above, asingle tab can be received within a slot or multiple tabs can bereceived within multiple slots.

Further, in FIG. 5, the footer 400 does not have to include an aperturein the flat leg to receive a securement mechanism, which may be a lagbolt, to extend through the aperture and into the slot of the track. Thefooter may have an aperture defined by a separate structure 403 that isintegrated between the upright leg and flat leg, as can be seen in FIG.5. The structure 403 has a diagonal surface that extends (e.g., at 45degrees) from the upright leg in a direction down to the flat leg.

Additionally in the embodiment of FIG. 5, the splice 200 has anextension 220 of the body at the lower end of the splice. This extensionis received with a track of the trim-rail 100. This can provide for astronger structural connection between the splice and the trim-rail.Extension 220 also covers slot 112B from direct view.

Dual Track Rail and Triple Track Rail Rail-Based Systems

This embodiment of a rail-based system includes one or more dual trackrails, which can be also referred to as a single rail, and one or moreunique clamps that may be interconnected to a footing grid. Thisembodiment is also disclosed in U.S. Pat. No. 8,128,044, the disclosureof which is expressly incorporated by reference herein.

FIG. 6 illustrates the rail-based system for removably and adjustablymounting a device on a surface in an operative environment. As shown,the system is an apparatus for removably and adjustably mounting one ormore photovoltaic modules on a surface such as a roof. Referringinitially to FIG. 6, the system for removably and adjustably mounting adevice on a surface is shown and generally designated 10. The system forremovably and adjustably mounting a device on a surface 10 includes atleast one rail 12. In a preferred embodiment, at least one rail 12 isformed of extruded aluminum, but the material used is not a materialconsideration to the invention. As shown perhaps best by cross-referencebetween FIGS. 8-12, at least one rail 12 is formed with at least twotracks 14 a,b, i.e., it is a dual track rail. Both of at least twotracks 14 a,b include a channel 16 a,b, perhaps best shown in FIGS. 8and 9, extending the length of at least one rail 12 substantiallycoincident with the longitudinal axis of at least one rail 12. Eachchannel 16 a,b in at least two tracks 14 a,b is formed with a slot 18a,b. Slots 18 a,b extend the length of at least one rail 12substantially coincident with the longitudinal axis of at least one rail12. In addition, slot 18 a in channel 16 a of at least one rail 12 isformed substantially at a right angle A to slot 18 b in any other of atleast two tracks 14 a,b, as shown diagrammatically in FIG. 8. As shownin FIGS. 8, 9 and 12, at least one rail 12 is formed with a body 20.Body has a proximal end 22, a distal end 24, and a hollow chamber 26between proximal end 22 and distal end 24 of body 20. Hollow chamber 26contributes to the light weight yet structural rigidity of at least onerail, and therefore to its ease of handling during installation ofsystem for removably and adjustably mounting a device on a surface 10.In a preferred embodiment, at least one rail 12 also is formed withopposing sides 28 a,b and opposing shoulders 30 a,b.

As further shown in FIG. 8, body 20 includes channel 16 b formed inopposing side 28 b for slidably engaging the rail on hardware describedbelow. Channel 16 b is formed with slot 18 b extending along thelongitudinal axis of at least one rail 12. In a preferred embodiment,slot 18 a,b also includes opposing jaws 32 a,b monolithically protrudingfrom slot 18 a,b substantially along the longitudinal axis of thechannel 16 a,b. Body 20 further includes channel 16 a. Channel 16 a isformed in opposing shoulder 30 a as shown in FIGS. 8 and 9. Channel 16 aalso contributes, in combination with channel 16 b, to making at leastone rail 12 slidably engageable with the one or more footings 36. Aswill be apparent to a person skilled in the art, channel 16 a andchannel 16 b enable at least one rail 12 to be slidable engageable withone or more footings 36.

As also shown by cross-reference among FIGS. 13-16, a system forremovably and adjustably mounting a device on a surface 10 also includesone or more clamps 34 a,b. As shown best by reference to FIGS. 13 and15, one or more clamps 34 a are formed as a duct 42. Duct 42 includes atleast two opposing flanges 44 a,b. Opposing flanges 44 a,b of one ormore clamps 34 a are substantially perpendicular to one another. One ormore clamps 34 a may also be described as formed with a plate 46 andmonolithic opposing side walls 48 extending substantially in the samedirection at substantially right angles B from plate 46. Opposing sidewalls 48 include a lower inner edge 50 and an upper face 52. A fin 54extends from upper face 52 substantially along the longitudinal axis ofone or more clamps 34 a,b. One or more clamps 34 a also includes atleast one hole 56 through plate 46 for securing one or more clamps 34 aas described below.

In an alternative embodiment of one or more clamps, one or more clamps34 b is formed with a leg 58 having a base 60 as shown best in FIG. 16.From base 60 of leg 58 a descending member 62 monolithically extendsfrom base 60. In addition, from base 60 of leg 58 an ascending member 64monolithically extends from base 60 in a direction substantiallyopposite the direction of descending member 62. As also shown in FIG.16, one or more clamps 34 b include means 66 for connecting base 60 toat least one rail 12. One or more clamps 34 b also includes means 70 forvariably positioning one or more clamps 34 b in channel 16 a of at leastone rail 12.

FIG. 6 also shows a device 68 that may be mounted on surface 40 usingthe rail-based system. In a preferred embodiment of the presentinvention, device 68 is a photovoltaic module 68′, also shown in FIG. 7.Photovoltaic module 68′ is formed with an edge 72. In a photovoltaicenvironment for application of the rail-based system, edge 72 holds oneor more photovoltaic panels 74. As also shown best in FIGS. 6 and 7,footing grid 38 includes one or more footings 36. In combination, theone or more footings 36 compose a network of keepers 76. In thepreferred embodiment, each of the network of keepers 76 is L-shaped andconstructed of metal. Neither the shape nor material of the keepers 76is a material limitation of the system. Each of keepers 76 may befastened to surface 40. If surface 40 is a roof of a building, keepers76 may be attached to surface 40 by inserting lag bolts (not shown)through keepers 76 into rafters 78 beneath surface 40. Once installed,keepers 76 form a grid, as shown in FIG. 1, on which at least one rail12 of the present invention is removably connectable.

Using the principal embodiment of the system, in operation one or moreclamps 34 a,b are variably positionable not only on at least one rail12, but also on footing grid 38 for demountably securing module 68′ tofooting grid 38, as shown by reference to FIG. 6. As shown in FIG. 14, apreferred embodiment of fin 54 a,b includes a serrated surface 55 thatgrips edge 72 of module 68′ with significant torsional rigidity, butbecause of the use of conventional hardware for attaching one or moreclamps 34 a,b to edge 72 of module 68′, one or more clamps 34 a,b arequickly and safely repositionable. As further shown by cross-referencebetween FIGS. 6 and 9, channel 16 a, during installation, may beslidably engaged with at least one rail 12 and to footing grid 38. Asshown in FIG. 9, slot 18 a includes opposing jaws 32 a,b monolithicallyprotruding from slot 18 a substantially along the longitudinal axis ofchannel 16 a. Jaws 32 a,b contribute to making one or more clamps 34 a,bslidable and removably engageable, and therefore allow the system to benot only mounted, but reconfigured on surface 40. Channel 16 b alsocontributes, in combination with first channel 16 a, to making at leastone rail 12 slidably engageable, and repositionable, with one or moreclamps 34 a,b. As will be apparent to a person skilled in the art,channel 16 a and channel 16 b enable at least one rail 12 to be slidableengageable with not only one or more clamps 34 a,b, but also withfooters 36 comprising footing grid 38.

While the system for removably and adjustably mounting a device on asurface 10 as shown in drawing FIGS. 6 through 16 is one embodiment ofthe rail-based system, it is only one such embodiment, it is notintended to be exclusive, and is not a limitation of the system. Theparticular system for removably and adjustably mounting a device on asurface as shown and disclosed in detail in this instrument is fullycapable of obtaining the objects and providing the advantages stated,but this disclosure is merely illustrative of the presently preferredembodiments of this system invention, and no limitations are intended inconnection with the details of construction, design or composition.

Further optimizations in connection with the system are achieved byincluding features and elements desirable for increasing the range andvariety of different applications and environments in which the systemmay be used. In at least one such additional optimization of the system,an apparatus and method for positioning a module on an object isprovided. The rail-based system includes one or more rails having atleast three rails (a “triple track rail” or “triple track rails”) usedin combination with at least one connector bracket.

FIG. 17 illustrates the apparatus for positioning a module on an objectin an operative environment. As shown, the system includes an apparatusfor removably and adjustably mounting one or more photovoltaic moduleson an object such as a pole or roof. Referring initially to FIG. 17, theapparatus for positioning a module on an object is shown and generallydesignated 100. The apparatus 100 for positioning a module 68′ on anobject includes at least one rail 102. In a preferred embodiment, atleast one rail 102 is formed of extruded aluminum, but neither thematerials used nor the extrusion method of manufacture is material tothe system.

As shown perhaps best by cross-reference among FIGS. 18, 19A and 19B, atleast one rail 102 is formed with at least three tracks 104 a,b,c, i.e.,it is a triple track rail which can be also referred to as a singlerail. Two of at least three tracks 104 a,b,c include a channel 106 a,b.For illustrative purposes, as best shown by cross-reference among FIGS.18, 19A and 19B, two of the at least three tracks 104 a,b,c are shownwith channels 106 a,b extending the length of at least one rail 102substantially parallel to the longitudinal axis of at least one rail102. Each channel 106 a,b in at least two tracks 104 a,b is formed witha slot 108 a,b that for illustrative purposes are shown as slots 108a,b. Slot 108 a,b extends the length of at least one rail 102substantially parallel to the longitudinal axis of at least one rail102. In addition, slot 108 a in channel 106 a of at least one rail 102is formed substantially at a right angle A to slot 108 b as showndiagrammatically in FIG. 19B.

As shown in FIGS. 18, 19A and 19B, at least one rail 102 also is formedwith a body 110. Body 110 has a proximal end 112, a distal end 114 asbest shown in FIG. 18, and a hollow chamber 116 between proximal end 112and distal end 114 of body 110 as best shown in FIG. 19B. Hollow chamber116 contributes to the light weight yet structural rigidity of at leastone rail, and therefore to its ease of handling during installation ofapparatus while positioning a module 68′ on an object. In a preferredembodiment, as best shown in FIGS. 18 and 19B, at least one rail 102also is formed with opposing sides 118 a,b and opposing shoulders 120a,b. In operation, as further shown in FIGS. 19B and 20, tracks 104 a,bpermit at least one rail 102 to be slidably engageable on hardwaredescribed below.

In a preferred embodiment, as shown by cross-reference between FIGS. 18and 19B, slot 108 a,b also includes opposing jaws 122 a,b monolithicallyprotruding from slot 108 a,b substantially along the longitudinal axisof channel 106 a,b. Channel 106 a is formed in opposing shoulder 120 aas shown in FIG. 19B. Channel 106 a also contributes, in combinationwith channel 106 b, to making at least one rail 102 slidably engageablewith the one or more footers 36.

Apparatus for positioning a module on an object 100, as shown bycross-reference between FIGS. 18 and 19B, also includes a cavity 124formed in body 110 of at least one rail 102. Cavity 124 is formedthrough at least one opposing side 118 a,b, and for illustrativepurposes is shown in FIG. 19B as being formed through at least oneopposing side 118 b. As also shown in FIG. 19B, an opening 126 is formedin opposing side 118 b. Opening 126 in opposing side 118 b is defined bya boss 128 also formed in opposing side 118 b as well as by a shelf 130.In a preferred embodiment, shelf 130 is formed monolithically from edge132 in opposing side 118 b that is opposite boss 128. Shelf 130 alsoextends monolithically into hollow chamber 116 to form a partition 134that is best shown in FIG. 19B. Partition 134 merges monolithically intobeam 136 in slot 108 a, as best shown in FIG. 19B.

In addition, as also shown in FIG. 19B, a beam 138 extends throughhollow chamber 116 between opposing sides 118 a,b of rail 102. Inoperation, beam 138 resists compressive and similar forces appliedagainst rail 102, thus enhancing the rigidity and longevity of apparatusfor positioning a module on an object 100 when installed. Also in apreferred embodiment, hollow chamber 116 is formed with a substantiallysemicircular passage 140, as best shown in FIGS. 18 and 19B. Inoperation, use of semicircular passage 140 instead of, for example, apassage having a rectangular shaped cross-section, also contributes toresisting compressive and other forces on apparatus for positioning amodule on an object 100 after installation and mounting of rail 102 onmodule 68′. In a preferred embodiment, at least one semicircular groove142 is formed in at least one of the opposing sides 118 a,b as shown inFIG. 18, for assisting an installer in drilling one or more additionalholes (not shown) through opposing sides 118 a,b for securing a mountingdevice (not shown) in which electrical or other lines may be secured.

Also included in the rail-based system for positioning a module on anobject 100 are one or more connector brackets 144, as shown bycross-reference between FIGS. 19B and 20. One or more connector brackets144 is formed to be demountably attachable to at least one rail 102 andto device 68 or module 68′. To achieve that object, one or moreconnector brackets 144 is monolithically formed with a first flange 146and a second flange 148 substantially at a right angle as showndiagrammatically as Angle B in FIG. 20. First flange 146 is formed witha lip 150. In addition, first flange 146 is formed with a bore 152. Inoperation, bore 152 is provided for insertion of a fastener 153 throughbore 152 to secure connector bracket 144 to device 68 or module 68′. Ina preferred embodiment, one or more connector brackets 144 furthercomprises an elbow 154. Elbow 154 is substantially L-shaped, and extendsmonolithically at substantially a right angle from second flange 148 asshown diagrammatically as Angle C in FIG. 20. Elbow 154 is shaped andconfigured for detachable engagement with cavity 124 formed in hollowchamber 116 of body 110. As shown best in FIG. 19B, elbow 154 isengageable with boss 128 as well as beam 136.

In operation, with respect to FIGS. 17-21, as will be evident to oneskilled in the art, the unique combination of one or more connectorbrackets 144, cavity 124, and three tracks 104 formed in at least onerail 110 (collectively, the “combined components”) permits installationof apparatus for positioning a module on an object 100 in a wide varietyof alternative ways. For example, as shown in FIG. 21, module 68′ istypically formed with a collector side 156 and a back side 158. The term“collector side” refers generally to that side of module 68′ thatcollects solar energy radiation from the sun. The term “back side”refers generally to that side of module 68′ that does not collect solarenergy radiation from the sun. The combined components permit aninstaller to select module 68′ having at least collector side 156 andback side 158, constructed with at least two opposing edges 160 a,bhaving a plurality of holes 162 a,b. The combined components permit aninstaller to position module 68′ collector side 156 down, mount at leastone rail 102 on the back side 158 of module 68′, and reposition thecombined components collector side 156 up to install the combinedcomponents on the object 68. Alternatively, the combined componentsallow an installer to install the components either top down or bottomup.

Low Profile Rail Rail-Based System

This embodiment of a rail-based system includes a low profile, sharedrail. This embodiment is also disclosed in U.S. Pat. No. 7,600,349, thedisclosure of which is expressly incorporated by reference herein.

As shown in FIGS. 22 through 34, a low profile mounting system isprovided that in its broadest context includes at least one rail 12,which can be a shared rail. At least one track 14 is formed in rail 12with opposing jaws 16 a b. Opposing jaws 16 a,b define a slot 18.Opposing jaws 16 a,b are disposed in rail 12 asymmetrically to thelongitudinal axis of rail 12 and to each other. At least one ledge 20monolithically extends from rail 12 for holding an object such as theframe 22 of a solar panel 24. A coupler 26 is provided for demountablyconnecting solar panel 24 to rail 12. A cleat 28 also is provided forattaching the low profile mounting system to a surface 30. A connectorconnects rail 12 to cleat 28.

As shown in FIG. 22, rails 12 a, b are mounted on a surface 30. Surface30 is a roof 34. FIG. 22 also shows solar panels 24 a, b bounded byframes 22 a, b. During installation frames 22 a, b are connected torails 12 a, b. Rails 12 a, b are secured to roof 34. In general, rails12 a, b are secured to roof 34 in part using footers or footings (inthis document, a “footing 36”). A number of footings 36 a, btraditionally have been used to secure rails 12 a, b to roof 34.Footings 36 a, b may be L-shaped and constructed of metal or othermaterials. Footings 36 a, b may be attached to roof 34 by inserting lagbolts (not shown) through passages (not shown) in footings 34 a, b intorafters 38 beneath roof 34.

As also shown in FIG. 22, in a conventional mounting configuration,solar panels 24 a, b are mounted top-down onto rails 12 a, b. This maypresent an aesthetically displeasing appearance because solar panels 24a, b and rails 12 a, b present an undesirably excessive elevation. Whatis desirable is to easily, quickly, and securely mount solar panels 24a, b on a surface 30 that produces a low profile that is comparativelyinconspicuous and as indiscernible as possible.

Low profile mounting system 10, as shown in different embodiments inFIGS. 23 through 34, allows an installer to achieve a low profile thatis comparatively inconspicuous and as indiscernible as possible.

In the embodiment of low profile mounting system 10 illustrated bycross-reference between FIGS. 23 and 24, rail 12 is shown to bemountable on a surface 30 known as a stanchion or stand-off (in thisdocument, a “stanchion 40”) rather than on roof 34. Stanchion 40 isuseful because of the aforementioned variety of materials used tomanufacture a roof 34 and coverings for roof 34. For example, if thecovering for roof 34 is made of tile, bolting a rail 12 directly to atile on roof 34, through a tile (not shown), is undesirable because thetiles may crack or break. To avoid that problem, one or more tiles areremoved, stanchion 40 is installed on roof 34, and solar panel 24 isattached to stanchion 40.

To achieve a lower profile than conventional installation apparatusallow, in the embodiment of low profile mounting system illustrated bycross-reference between FIGS. 23 and 24, rail 12 is shown to include atleast one ledge 20. As shown, rail 12 is formed with an upper surface44, a lower surface 46, and opposing walls 48 a,b monolithicallyconnected to upper surface 44 and lower surface 46. At least one ledge20 extends at a substantially right angle from opposing walls 48 a,b inopposite directions from the longitudinal axis through rail 12. Ratherthan mount solar panel 24 top-down, thus raising the total elevation ofan installed mounting system, at least one ledge 20 b allowsinstallation of frame 22 of solar panel 24 closer to surface 30.

As also shown in the embodiment shown in FIGS. 23 and 24, rail 12includes plurality of tracks 14 a, b. Plurality of tracks 14 a, b isformed in rail 12 with opposing jaws 16 a-d defining slots 18 a, b. Inaddition, in the embodiment shown in FIGS. 23 and 24, opposing jaws 16a, b and opposing jaws 16 c, d are disposed in rail 12 asymmetrically toeach other and to the longitudinal axis of rail 12. The term“asymmetrically” as used in this document means that slot 18 a isdirectionally disposed differently than slot 18 b. As indicated, atleast one coupler 26 is provided. Coupler 26 includes an attachmentdevice 50. In the embodiment shown in FIGS. 23 and 24, attachment device50 is a first bolt 52 and a first nut 54. Coupler 26 also includes aclamp 56. Clamp 56, as shown in FIGS. 23 and 24, is substantially aU-shaped gutter 56 a formed with an orifice 58 and opposing fins 60. Thehead 62 of first bolt 52 is slidably insertable into slot 18 a of track14 to extend through opposing jaws 16 a, b and, by deploying first nut54 on first bolt 52, U-shaped gutter 56 a may be clamped into ducts 64a, b formed on a conventional frame 22 of solar panel 24. Clamp 56 asshown in all embodiments of low profile mounting system 10 may be ashort segment, or may extend the entire length of rail 12 to enhance theaesthetic appearance of an installed low profile mounting system 10, andto aid in resisting wind and rain penetration into the components of lowprofile mounting system 10.

FIGS. 23 and 24 also show that a second bolt 66 and a second nut 68 areincluded. Head 70 of second bolt 66 is slidably insertable into track 14b to extend through slot 18 b. An opening 72 is provided in an extension74 of stanchion 40. Second bolt 66 is inserted through opening 72,second nut 68 is inserted on second bolt 66, and the embodiment of lowprofile mounting system 10 as shown in FIGS. 23 and 24 is securelyattached to stanchion 40, which in turn has been attached to roof 34.Solar panel 24 thus provides a low visual profile.

In the embodiment low profile mounting system 10 illustrated bycross-reference to FIGS. 25 and 26, low profile mounting system 10 isshown to include a plurality of ledges 20 a, b on rail 12 for holding apair of solar panels 22 a and 22 b. In this sense, mounting system 10 isa “shared” rail system. FIGS. 25 and 26 also show an embodiment of lowprofile mounting system 10 that includes at least one cleat 28. Further,the embodiment shown in FIGS. 25 and 26 shows a clamp 56 b in the formof a substantially flat planar surface or plate 76. Clamp 56 b isanother embodiment of clamp 56 useful in providing a pleasingconfiguration to an assembled low profile mounting system 10 and forsecuring ducts 64 a, b of a plurality of frames 22 a, b on plurality ofledges 20 a, b on rail 12. Further, cleat 28 includes at least one hole78. As shown, cleat 28 includes holes 78 a, b, c. Holes 78 a, b are usedto attach cleat 28 to roof 34 using lag bolts or similar connectors.Hole 78 a is used to attach cleat 28 to rail 12 by inserting second bolt66 into slot 18 b and through hole 78 c, and attaching second nut 68 tosecond bolt 66. As a result, a secure, easily installable, andaesthetically pleasing installation of low profile mounting system 10 isachieved.

In another embodiment of low profile mounting system 10, as shown inFIGS. 27 and 28, an alternative clamp 56 is provided as clamp 56 c.Clamp 56 c is useful in connection with variations of frame 22 formedwith a plurality of ducts 64 a, b as shown best in FIG. 28. Clamp 56 calso is formed as a gutter, but with opposing arms 80 a, b long enoughto be removably insertable into ducts 64 a, b to hold frame 22 of solarpanel 24 tightly against ledge 20 a, b when locked into position usingattachment device 50.

In the embodiment of low profile mounting system 10 illustrated in FIGS.29 and 30, clamp 56 a, as shown by cross-reference between FIGS. 23 and24 in connection with a single frame 22 of solar panel 24 being attachedto stanchion 40, is shown to be equally useful when disposed in aconfiguration in which a plurality of opposing frames 22 c, d aremounted on a rail 12 that in turn is mounted on cleat 28 for attachmentto roof 34.

In another embodiment of low profile mounting system 10, as shown bycross-reference between FIGS. 31 and 32, rail 12 is shown with a track14 b and a longitudinal cavity 82 formed in upper surface 44 of rail 12c. As shown, longitudinal cavity 82 is shaped to receive an attachmentdevice 50. Attachment device 50, as shown in FIG. 32, includes firstbolt 52. A receptor body 84 also is monolithically formed adjacentlongitudinal cavity 82. As shown in FIG. 32, first threads 86 are formedin receptor body 84 for matable connection with second threads 88 formedon first bolt 52. Further, as also shown in FIG. 32, clamp 56 d isformed with a contoured cross-sectional configuration for bothaesthetics and for gripping frame 22 of solar panel 24 a, b, andincludes parallel nubs 90 a, b. Parallel nubs 90 a, b are designed tofit tightly along exterior surfaces 92 a, b of longitudinal cavity 82.

In the embodiment of low profile mounting system 10 illustrated in FIGS.33 and 34, longitudinal cavity 82 a is shown to be useful as a scribeguide 94 for inserting into rail 12 an attachment device 50 in the formof a screw 50 e. As shown, receptor body 84 also includes a groove 96.As also shown, two detents 98 a, b are formed in receptor body 84. Avariation of clamp 56 d, namely 56 e, is provided with comparativelylonger parallel nubs 90 c, d that are insertable into two detents 98 a,b in receptor body 84. Receptor body 84 also includes opposing fins 100a, b. Screw 50 e is removably insertable through clamp 56 e intoreceptor body 84. Screw 50 e extends into the chamber 102 formed in rail12. Screw 50 e is held in place in part by opposing fins 100 a, b.

In all embodiments shown in FIGS. 22 through 34, end plates 104, as bestshown in FIG. 31, may be placed across low profile mounting system 10 tofurther add to the aesthetic appearance of an assembled low profilemounting system 10, and to preclude entry of water, wind, and otherelements into low profile mounting system 10.

Although FIGS. 22 through 34 shows embodiments of low profile mountingsystem 10 in which components of low profile mounting system 10 are incertain positions in relationship to one another, the components may belocated in any number of other positions. Although the number ofalternative attachment devices and connectors are shown, other fastenersmay be used. The low profile mounting system shown in drawing FIGS. 22through 34 includes a number of non-exclusive embodiments that aremerely illustrative of the disclosed low profile mounting system 10.

Rail-Less or Non-Rail-Based System Components

FIG. 35A is a cross-section of an embodiment of a rail-less or anon-rail-based system or apparatus 10 for mounting photovoltaic modules,with a photovoltaic module 1 mounted thereon, in accordance with anembodiment of the rail-less system. This embodiment of a rail-less ornon-rail-based system is also disclosed in U.S. patent application Ser.No. 14/515,990, filed on Oct. 16, 2014, the disclosure of which isexpressly incorporated by reference herein.

In FIG. 35A, the apparatus 10 includes a bracket 100 (micro-rail), aclamp 200, and a footer 400. An attachment mechanism 300 secures theclamp 200 to the bracket 100.

In FIG. 35A, the bracket 100 defines slots 112A and 112B on opposingsides of the bracket 100 in a lower portion 110A of the bracket 100.Slots 112A and 112B extend along an entire longitudinal length L of thebracket 100, as can be seen at least in FIG. 36.

In FIG. 35A, the bracket 100 includes a first ledge 120 on a first side110C of the bracket 100 and a second ledge 122 on a second, opposingside 110D of the bracket 100. The opposing sides extend along thelongitudinal length of the bracket 100 and between the lower portion110A and an upper portion 110B of the bracket 100. The bracket 100defines a cavity 130 between the upper portion 110B of the bracket 100and the lower portion 110A of the bracket 100 and includes an extensionmember 140 on the upper portion 110B of the bracket 100. The extensionmember 140 defines a cavity 142 within the extension member 140.

In FIG. 35A, as mentioned above, the apparatus 10 also includes a clamp200 that is securable onto the bracket 100 and on the upper portion 110Bof the bracket 100. The clamp 200 includes two opposing legs 210, 212where the extension member 140 of the bracket 100 is disposed betweenthe two opposing legs 210, 212 of the clamp 200 when the clamp 200 issecured to the bracket 100. A plurality of attachment mechanisms 300, ascan be seen in FIG. 36, secure the clamp 200 to the bracket 100 on theupper portion 110B of the bracket 100. The attachment mechanisms may bebolts or screws.

In FIG. 35A, the clamp 200 also includes a first wing 220 on a firstside 200A of the clamp 200 and a second wing 222 on a second side 200Bof the clamp 200. As will be further discussed below, the wings 220, 222cooperate with the ledges 120, 122 of the bracket 100, respectively, tosecure multiple photovoltaic modules in the apparatus 10. Clamp 200 alsoextends along the entire longitudinal length L of the bracket 100, ascan be seen in FIG. 36, and thus, along the entire longitudinal lengthof the apparatus 10.

In FIG. 35A, the apparatus 10 also includes a footer 400, as mentionedabove. The footer 400 is variably positionable on the bracket 100 alongeither slot 112A or 112B, as can be further seen in FIGS. 36-42. Thefooter 400 is generally L-shaped with a first, upright leg 401 and asecond, flat leg 402. The upright leg 401 is “upright” in the sense thatit extends perpendicularly to the surface on which the footer 400 ismounted. The flat leg 402 is “flat” in the sense that it extendsparallel to the surface on which the footer 400 is mounted. The uprightleg contains at least one aperture, through which a securement mechanism410, which may be a bolt and a nut, extends. As shown in FIG. 36, two,or more, apertures may be provided, such that the position of thebracket 100 with respect to the upright leg 401 of the footer 400 may beadjusted by use of the securement mechanism in the different apertures.The shaft of the bolt extends through an aperture of the upright leg 401and the nut, or other structure, of the securement mechanism 410 isdisposed within the slot 112A of bracket 100, or slot 112B if the footer400 is placed on the opposing side of the bracket 100. As the bolt isthreaded down on the nut, the footer 400 is secured at a position on thebracket 100 along the slot 112A. The flat leg 402 of the footer alsocontains an aperture, and an additional securement mechanism, which maybe a lag bolt, extends through the aperture and into a roof structure,e.g., a rafter, to secure the flat leg 402, and thus the footer 400, tothe roof structure.

Thus, in FIG. 35A, as discussed above, the footer 400 is variablypositionable on the bracket 100 along the slot 112A via the securementmechanism 410 that is disposed through the footer 400 and is received inthe slot 112A. By loosening the nut on the bolt, while the nut remainsin slot 112A, the footer and securement mechanism may be moved andpositioned anywhere along the longitudinal length of the bracket, andthen tightened to secure the footer 400 on the bracket 100 at a desiredpositioned. This provides a benefit since, as will be further discussedlater in this specification, the footer is not constrained to a singleposition on the bracket, but rather, it can be variably positioned onthe bracket such that it can be co-located at the position of a roofstructure, e.g., a rafter, to which the footer is to be mounted.

In FIG. 35A, further included in apparatus 10 are first bonding clip 500and second bonding clip 510. First bonding clip 500, and first andsecond bonding clips 500, 510, can be seen in FIG. 35B and at least inFIG. 36. The first bonding clip 500 and the second bonding clip 510 areboth disposed only on the first side 110C of the bracket 100 and aredisposed on opposing longitudinal ends of the first ledge 120 of thebracket 100. Bonding clips 500, 510 include similar structure, and ascan best be seen in FIGS. 1A and 1B, the first bonding clip 500, andthus second bonding clip 510, includes teeth 512 on an upper side 520and a lower side 522 of the bonding clips. As can be particularly seenin FIG. 35B, the first bonding clip 500 and the second bonding clip 510are each formed generally in a U-shape.

As can be seen at least in FIG. 35A and FIG. 35C, the first ledge 120 ofthe bracket 100 includes a depression 120A on its upper side and aportion of the first bonding clip 500 is disposed in the depression120A. Similarly, a portion of the second bonding clip 510 is alsodisposed in the depression 120A at an opposite longitudinal end of thedepression 120A. As will be further discussed below, bonding clips 500,510 electrically bond the photovoltaic modules to the apparatus 10.

As can be seen at least in FIG. 37, the first ledge 120 of the bracket100, the second ledge 122 of the bracket 100, the first wing 220 of theclamp 200, and the second wing 222 of the clamp 200 each extend alongthe entire longitudinal length of the apparatus 10. With this structureof the apparatus 10, as can be seen when considering at least FIG. 35A,FIG. 36, and FIG. 44, a first photovoltaic module 1 and a secondphotovoltaic module 2 are mountable on the first side 110C of thebracket 100 and the first side 200A of the clamp 200 between the firstledge 120 of the bracket 100 and the first wing 220 of the clamp 200where the first photovoltaic module 1 is adjacent to the secondphotovoltaic module 2.

In FIG. 35A, the he securement mechanisms 300 are threaded intorespective apertures in clamp 200 and extension member 140 of bracket100 to lower the clamp 200 with respect to bracket 100, and thus, clampthe photovoltaic modules 1, 2 between the first ledge 120 of bracket 100and first wing 220 of clamp 200. Securement mechanisms 300 alsoelectrically bond the clamp 200 to the bracket 100.

As can be understood when considering FIG. 36, when the firstphotovoltaic module 1 and the second photovoltaic module 2 are clampedbetween the first ledge 120 and first wing 220, the teeth 512 on theupper side 520 of bonding clip 500 engage with the first photovoltaicmodule 1 and the teeth 512 on the lower side 522 of bonding clip 500engage with ledge 120. Similarly, the teeth 512 on the upper side 520 ofbonding clip 510 engage with the second photovoltaic module 2 and theteeth 512 on the lower side 522 of bonding clip 510 also engages withledge 120. As such, the photovoltaic modules 1, 2 are electricallybonded to the apparatus 10 through bonding clips 500, 510.

As can also be understood particularly when considering FIGS. 43 and 44,on the opposing, second side 110D of the bracket 100 and the opposing,second side 200B of the clamp 200, a third photovoltaic module 3 and afourth photovoltaic module 4 are mountable on the second side 110D ofthe bracket 100 and the second side 200B of the clamp 200 between thesecond ledge 122 of the bracket 100 and the second wing 222 of the clamp200, where the third photovoltaic module 3 is adjacent to the fourthphotovoltaic module 4.

As such, the apparatus 10 can be disposed between 3 or 4 photovoltaicmodules of an array of photovoltaic modules to mount the 3 or 4photovoltaic modules to a roof structure. Thus, respective corners ofthe 3 or 4 photovoltaic modules are secured in the apparatus 10. If theapparatus 10 is used on the edge of the array, only 2 photovoltaicmodules are mounted in the apparatus on one side of the apparatus.

FIG. 37 is a perspective view of the apparatus 10 for mountingphotovoltaic modules of FIG. 35A in a first position of the footer 400with respect to the bracket 100. As discussed above, the footer 400 isvariably positionable on the bracket 100 along the slot 112A. As shownin FIG. 37, the footer 400 is positioned at the far left side of thebracket 100 along slot 112A in this Figure.

FIGS. 38 and 39 show the footer 400 positioned at other locations on thebracket 100 along the slot 112A. In FIG. 38, the footer 400 ispositioned in the middle of the bracket 100 along slot 112A and in FIG.39 the footer 400 is positioned at the far right side of the bracket 100along slot 112A. It is only required that one footer be used in theapparatus 10.

FIGS. 40-42 correlate to FIGS. 37-39, respectively, regarding thepositioning of the footer 400 with respect to the bracket 100. As can beunderstood, when the apparatus is used on a roof to mount photovoltaicmodules on the roof, the bracket 100 may not always align with a rafterA of the roof at the same position on the bracket 100. Thus, with thepresent invention, the footer 400 is variably positionable on thebracket 100 such that the position of the footer 400 can be co-locatedwith the position of the rafter A.

FIG. 43 illustrates an alternative embodiment of an apparatus 10A formounting photovoltaic modules in accordance with the principles of thepresent invention. The same reference characters are used for the sameelements for the embodiments of FIGS. 35A and 43.

As can be seen, the apparatus 10A of FIG. 43 includes the same elementsas the apparatus 10 of FIG. 35A. A difference between the embodiments isthe longitudinal length A of the apparatus of the two embodiments. Inthe embodiment of FIG. 43, the longitudinal length A of apparatus 10A ismuch shorter than the longitudinal length of apparatus 10, thus it cangenerally be referred to as including a “short micro-rail”, which can beabout 3″ long. This is because, as can be seen in FIG. 44, and asdiscussed above, apparatus 10 (with a micro-rail) can be used to mountthree-four photovoltaic modules in both the East-West (E-W) directionand the North-South (N-S) direction. Apparatus 10A (with a shortmicro-rail) is only used to mount at-most two photovoltaic modules inthe N-S direction at the E-W ends of the photovoltaic array. Thus, theapparatus 10 is longer (e.g., 17.5 inches) than apparatus 10A (e.g., 3inches) to provide greater support for the mounted photovoltaic modules.Another difference is that apparatus 10A may only include a singlebonding clip 500.

As discussed above, in FIG. 43, the apparatus 10A includes the sameelements as apparatus 10. Thus, apparatus 10A includes a short bracket100 (short micro-rail), a clamp 200, and a footer 400 (not shown in FIG.43). An attachment mechanism 300 secures the clamp 200 to the bracket100.

In FIG. 43, the bracket 100 defines slots 112A and 112B on opposingsides of the bracket 100 in a lower portion 110A of the bracket 100.Slots 112A and 112B extend along an entire longitudinal length L of thebracket 100.

In FIG. 43, the bracket 100 includes a first ledge 120 on a first side110C of the bracket 100 and a second ledge 122 on a second, opposingside 110D of the bracket 100. The bracket 100 defines a cavity 130between the upper portion 110B of the bracket 100 and the lower portion110A of the bracket 100 and includes an extension member 140 on theupper portion 110B of the bracket 100. The extension member 140 definesa cavity 142 within the extension member 140.

In FIG. 43, the clamp 200 includes two opposing legs 210, 212 where theextension member 140 of the bracket 100 is disposed between the twoopposing legs 210, 212 of the clamp 200 when the clamp 200 is secured tothe bracket 100. An attachment mechanism 300 secures the clamp 200 tothe bracket 100 on the upper portion 110B of the bracket 100.

In FIG. 43, the clamp 200 also includes a first wing 220 on a first side200A of the clamp 200 and a second wing 222 on a second side 200B of theclamp 200.

As can be further seen in FIG. 44, a plurality of apparatuses 10 and 10Acan be used to mount an array of photovoltaic modules.

As can be seen in FIGS. 45-48, the apparatus 10, and 10A, may furtherinclude a trim assembly 600. The trim assembly 600 includes trim 610 anda trim mounting bracket 620. The trim mounting bracket 620 is mountableon the bracket 100 and the trim 610 is mountable on the trim mountingbracket 620.

As shown in FIG. 45, the trim 610 is an elongated structure with acurved form.

As shown in FIG. 46, the trim mounting bracket 620 includes two trimmounting structures 621, 622. Both of these mounting structures 621, 622are generally U-shaped. Trim mounting bracket 620 also includes twobracket mounting structures 623, 624. Mounting structure 623 isgenerally U-shaped and mounting structure 624 includes two legs thatboth have an outwardly extending tab on the ends of the legs. As can beseen in FIGS. 47 and 48, trim mounting bracket 620 is mounted on bracket100 by engaging bracket mounting structure 623 on a ridge 150 of thebracket 100 and by engaging bracket mounting structure 624 in the slot112A of the bracket 100. The outwardly extending tabs on the ends of thelegs of mounting structure 624 engage behind structure of the bracketthat defines slot 112A. As such, the trim mounting bracket 620 may beeasily positioned at different positions on the bracket 100, i.e.,adjusted East-West on the apparatuses, along slot 112A.

In FIG. 48, an attachment device 625, which may be a screw with apointed end, is disposed through an aperture in trim mounting bracket620 and within slot 112A to engage with bracket 100 internal to the slot112A. The screw cuts into the bracket 100 to electrically bond the trimmounting bracket 620 to the bracket 100.

In FIG. 48, the trim 610 is mounted in the trim mounting bracket 620 byplacing a lower portion 612 of the trim 610 in the lower trim mountingstructure 622 and by placing an upper portion 614 of the trim 610 in theupper trim mounting structure 621. Thus, the trim 610 can be snappedinto the trim mounting bracket 620 and no attachment holes are requiredin the trim 610, thus aesthetically enhancing the trim.

In FIG. 48, an attachment device 626, which may also be a screw with apointed end, is disposed through an aperture in trim mounting bracket620 and in engagement with the upper portion 614 of trim 610 that isdisposed within trim mounting structure 621. The screw cuts into thetrim 610 to electrically bond the trim 610 to the trim mounting bracket620, and thus the bracket 100.

In FIG. 48, a lowest-most portion 600A of the trim assembly 600 extendsbelow a lowest-most portion 100E of the bracket 100. As such, the trimassembly provides for a fire protection mechanism since the flow of airunder the mounting apparatus 10, 10A, and thus under the photovoltaicmodules that are mounted on the mounting apparatus 10, 10A, isrestricted by the trim assembly 600 which extends below the bracket 100.

In FIGS. 45-48, a longitudinal length of the trim 610 is much longerthan the longitudinal length A of the apparatus 10. As such, a singletrim 610 can extend across numerous apparatuses 10, 10A, and thus, bemounted across numerous adjacently mounted apparatuses. Further, theposition of trim 610 is East-West adjustable in the trim mountingbracket 620 depending upon the area it is to cover and can be cut tosize depending upon the area to be covered. Also, due to the curved formof the trim 610, adjacent trims 610 may overlap each other in anestable/telescoping manner when installed, or during storage andshipping of the trims. The nestable/telescoping feature allows one sizetrim to fit a variety of photovoltaic module lengths regardless ofportrait or landscape module orientation, without the need for cuttingthe trim to length; only positioning is required.

Further, in FIGS. 45-48, the East-West adjustability of the trimmounting bracket 620 on the apparatuses and the E-W adjustability of thetrim 610 within the trim mounting bracket 620 are also benefits. Furtheryet, the trim 610 helps to provide alignment of a plurality ofapparatuses 10, 10A that may be installed in a line, e.g., duringinstallation of a first row of photovoltaic modules in an array.

Additionally, in FIG. 49, the apparatus 10 may also include amicro-inverter mounting bracket 700, where the micro-inverter mountingbracket 700 is mountable on the bracket 100. As can be seen in FIGS. 49and 50, the micro-inverter mounting bracket 700 is generally L-shapedwith a first, upright leg 701 and a second, flat leg 702. The uprightleg 701 is generally perpendicular to the flat leg 702.

In FIG. 49, the micro-inverter mounting bracket 700, like trim mountingbracket 620, is also mountable in the slot 112A of the bracket 100. Theupright leg 701 of micro-inverter mounting bracket 700 has amicro-inverter mounting bracket mounting structure 711 at its lower end.This structure 711 is similar to structure 624 of trim mounting bracket620 for mounting in slot 112A. As such, mounting structure 711 alsoincludes two legs that both have an outwardly extending tab on the endsof the legs.

As can be seen in FIG. 50, micro-inverter mounting bracket 700 ismounted on bracket 100 by engaging micro-inverter mounting bracketmounting structure 711 in the slot 112A of the bracket 100. Theoutwardly extending tabs on the ends of the legs of mounting structure711 also engage behind the structure of the bracket that defines slot112A. As such, the micro-inverter mounting bracket 700, like trimmounting bracket 620, may be easily positioned at different positions onthe bracket 100, i.e., adjusted East-West on the apparatus.

In FIG. 49, an attachment device 720, which may be a screw with apointed end, is disposed through an aperture in leg 701 ofmicro-inverter mounting bracket 700 and within slot 112A to engage withbracket 100 internal to the slot 112A. The screw cuts into the bracket100 to electrically bond the micro-inverter mounting bracket 700 to thebracket 100.

In FIG. 49, the flat leg 702 of micro-inverter mounting bracket 700includes a flange 712 that receives within it an end of a mounting plate801 that is associated with a micro-inverter 800. When the end of themounting plate 801 is received within the flange 712, the plate 801rests on flat leg 702. An attachment device 722, which may be a screw ora bolt, is disposed through respective apertures in flat leg 702 andplate 801 to mount the micro-inverter 800 on the bracket 100, and thus,apparatus 10. This structure also serves to keep the micro-inverter at aproper height location relative to the roof, the apparatus, and thephotovoltaic module that the micro-inverter is associated with. Theattachment device 722 also electrically bonds the mounting plate 801 ofmicro-inverter 800 to the micro-inverter mounting bracket 700.

In FIG. 49, also similar to trim mounting bracket 620, micro-invertermounting bracket 700 is East-West adjustable on bracket 100. Further,the micro-inverter mounting bracket 700 may be installed on either sideof mounting bracket 100, i.e., either the North or South side.

Hybrid Solar Panel Mounting Assembly

As discussed above, the present invention provides a hybrid assembly forremovably and adjustably mounting solar panels on a surface.

The hybrid assembly consists of components of a “rail-based” system andcomponents of a “rail-less” or “non-rail-based” system. As discussed,utilizing a rail-based system component, e.g., a rail, in the front rowof a solar panel array provides a benchmark or baseline to construct theremaining solar array with the modules being in a more stable positionand it is easier to align and square the array and the modules.

By using rail-less or non-rail-based system components in the rest ofthe array, this allows the installer the flexibility to work aroundobstructions, e.g., vents, skylights, etc., without needing tocut/modify a rail. This also allows for mixing of the orientation of thesolar panel modules within a row.

Thus, in the hybrid solar panel mounting assembly of the presentinvention, a combination of rail-based system components and rail-lesssystem components are used to mount a plurality of solar panels in asolar panel array to a surface.

FIG. 51 illustrates a known configuration of a rail-less ornon-rail-based system. As can be seen, a plurality of photovoltaicmodules A are disposed in a solar panel array. A skirt 1 is disposed onthe first row of the modules. However, this skirt is not capable ofsupporting the modules on a surface because the skirt is merely attachedonly to the modules, and not to the surface. The skirt is used foraesthetic purposes and for providing for a fire protection mechanism byrestricting the flow of air under the photovoltaic modules on which thetrim is attached.

Further in the known configuration of the rail-less or non-rail-basedsystem of FIG. 51, the system includes short micro-rails 2 (shortbrackets 100 discussed previously, e.g., in FIG. 43) and micro-rails 3(brackets 100 also discussed previously, e.g., in FIG. 41), in additionto any other hardware described above for mounting the solar panels tothe short micro-rails and micro-rails. As described above, two adjacentsolar panel modules are mounted on the short micro-rails 2 and eithertwo or four solar panel modules are mounted on the micro-rails 3. Thus,only rail-less or non-rail-based system components are used in the knownconfiguration of FIG. 51. Because the various rail-less ornon-rail-based, and rail-based, system components have been describedpreviously, and since the components are generally fully disposed underthe solar panels of the solar panel array, the reference characters andreference lines that are associated with these components point to thelocations of these components in the array in the various embodiments.

FIGS. 52-59 disclose various configurations for the components of thehybrid solar panel mounting assembly of the present invention.

As shown in FIG. 52, the hybrid mounting assembly also includes shortmicro-rails 2 and micro-rails 3. Two adjacent solar panel modules aremounted on the short micro-rails 2 and either two or four solar panelmodules are mounted on the micro-rails 3. However, the hybrid mountingassembly of the present invention also includes components of arail-based system. In this embodiment, the component of the rail-basedsystem is the trim-rail 100 described earlier in this specification inFIG. 1, and represented in FIG. 52 by reference character 4. As such,the trim-rail 4 is used as the front-most rail in the hybrid solar panelmounting assembly of FIG. 52, and thus, on the first row of solar panelsin the array to mount the first row of solar panels. As such, trim-rail4 provides a benchmark or baseline to construct the remaining solararray with the modules A being in a more stable position and it iseasier to align and square the array and the modules. Use of thetrim-rail 4 in the hybrid mounting assembly also provides the otherbenefits discussed previously in this patent application.

In the context of the present invention, a rail, as defined above, is acomponent of a rail-based system. A micro-rail and a short micro-rail,as also defined above, are not components of a rail-based system sincethey are not rails. As such, the micro-rail and the short micro-rail,even though they contain the word “rail” in the names given in thisspecification for these components of a rail-less or non-rail-basedsystem, are not components of a rail-based system, but rather, arecomponents of a rail-less or non-rail-based system.

As shown in FIG. 53, the hybrid mounting assembly also includes shortmicro-rails 2 and micro-rails 3, as used in the embodiment of FIG. 52.However, the hybrid mounting assembly of this embodiment also includes arail 5 of a rail-based system, in addition to any other hardwaredescribed above for mounting the solar panels to the rail, as describedin embodiments earlier in this specification, or which can be embodiedas other embodiments of a rail. The rail 5 is only used to mount solarpanels A that are disposed on one side of the rail 5. Rail 5 extends theentire width of the solar panel array, encompassing three solar panelsin this embodiment, and thus, three rows of solar panels, and isdisposed on a North-South extending edge of the array. A trim on thefront of the array is optional.

The embodiment of FIG. 54 uses a shared rail 6 on the first row of solarpanels and also includes short micro-rails 2 and micro-rails 3, asshown.

The embodiment of FIG. 55 uses two shared rails 6 on the first two rowsof solar panels and also includes short micro-rails 2 and micro-rails 3.Thus, the adjacent solar panels of the first two rows are mounted on thesecond rail 5.

The embodiment of FIG. 56 uses a shared rail 6 on the first row of solarpanels and also includes short micro-rails 2 and micro-rails 3 at thecorners of a hole or obstruction in the solar panel array. Thus, here,the use of the micro-rails 3 allows the installer the flexibility towork around the hole or obstruction without needing to cut/modify anyrails. However, the rail is still used in the assembly, as discussedabove.

The embodiment of FIG. 57 uses shared rails 6 on the front edge of thefirst row of solar panels and on the back edge of the last row (at theNorth end) of solar panels. A trim-rail is used on the front edge of thefirst row of solar panels. The rails again extend across the three solarpanels of the respective row. The assembly also includes shortmicro-rails 2 and micro-rails 3.

The embodiment of FIG. 58 uses a shared rail 6 between the first tworows of solar panels and uses a trim-rail 4 on the front edge of thefirst row of solar panels. Thus, the adjacent solar panels of the firsttwo rows are mounted on the rail 5. Short micro-rails 2 and micro-rails3 are also used.

The embodiment of FIG. 59 uses a trim-rail 4 on the first row of solarpanels and also includes short micro-rails 2 and micro-rails 3 at thecorners of a hole or obstruction in the solar panel array.

Of course, other embodiments of combinations of components of arail-based mounting system and a rail-less mounting system can becontemplated within the scope of the present invention.

Additional Rail-Less or Non-Rail-Based System Components

FIGS. 60-62 illustrate an embodiment of a height adjustable solar panelmounting assembly in accordance with the principles of the presentinvention. This height adjustable mounting assembly can be used as amicro-rail 3 and a short micro-rail 2, i.e., brackets, of the presentinvention. As can be seen, the assembly 3010 includes an upper bracket3100, a lower bracket 3200 (which together form a mounting bracket formounting solar panels), a stanchion 3300, a helical drive 3400, and abase (track) 3500. First clamping bolt 3602 clamps the upper bracket3100 down to lower bracket 3200 when one or more solar panels areinstalled in slots 10A, 10B. Second clamping bolt 3302 provides aclamping force to secure an “I ”-shaped side clamp 3310 to a bottomportion of stanchion 3300, i.e., when stanchion 3300 is secured ontobase 3500. Stop bar 3220 runs sideways across the width of lower bracket3200 and serves as a stop to abut against, and align, the solar panel(s)when installed in slot 10A. Stop bar 3220 also prevents the solarpanel(s) from touching the upper portion of stanchion 3300. Bonding pin3604 is disposed in a hole located in recessed channel 3222 in lowerbracket 3200. Bonding pin 3604 serves to pierce the anodized aluminumcoating on the solar panel and electrically interconnect (ground) thesolar panel to the lower bracket 3200 of assembly 3010.

In FIG. 61, the lower bracket 3200 has been removed from the view tomore clearly illustrate helical drive 3400 disposed within stanchion3300. Stanchion 3300 includes two vertical arms: first arm 3306 andsecond arm 3308. Disposed across the tops of arms 3306 and 3308 is anintegral bridge segment 3310 which connects across the two tops. Secondaperture 3312, located below a clamping wing of upper bracket 3100 andhaving a centerline that is co-linear with first aperture 3102, isdisposed within bridge 3310 and provides vertical access for tool 3600,e.g., an Allen wrench, to engage with a patterned, e.g., hexagonal,aperture 3402 in helical drive 3400.

FIG. 62 is a side view of the embodiment of the height adjustable solarpanel mounting assembly 3010 shown in FIGS. 60-61. Upper bracket 3100includes a vertical wall 3106 that has a lower end that engages with aslot 3201 that is disposed within, and lays across the width of, lowerbracket 3200. Lower bracket 3200 includes an integral pair of symmetricstiffening ribs 3202, 3204 disposed underneath the mounting plane 3207of lower bracket 3200, which serve to respectively stiffen the distalextents, i.e., wings 3240, 3242, of lower bracket 3200. Hollow space3210 is disposed (on both sides) in-between stiffening rib 3202, 3204and the horizontal plane (mounting plane 3207) of lower bracket 3200.Disposed in-between the two stiffening ribs 3202, 3204 is an integral,rectangular “box” 3206 that mechanically surrounds, engages, andsupports, i.e., couples, helical drive 3400 to lower bracket 3200. Theupper and lower interior horizontal ledges of box 3206 rest on, i.e.,couple to, the upper and lower horizontal surfaces of drive 3400,respectively. Support box 3206 transfers vertical motion of helicaldrive 3400 to vertical motion of lower bracket 3200.

In contrast to the embodiment of FIG. 62, in embodiments of the presentinvention, the upper bracket 3100 and the lower bracket 3200 can bemanufactured as a single, monolithic, integral part. This can bemanufactured as a single extrusion, for example.

Additional Trim-Rail Assembly

FIG. 63 illustrates a second embodiment of a trim-rail 4000 of thetrim-rail assembly of the present invention with integrated clamping.Trim-rail 4000 includes both a rail 4300 and a trim 4200 and integratedclamping ledges 4010, 4030 where the rail 4300, trim 4200, and clampingledges 4010, 4030 are integrated as a single, monolithic structure.Thus, the trim-rail 4000 includes a rail 4300 that extends an entirelength or width of at least one solar panel of a plurality of solarpanels that are utilized in a solar panel array. The rail 4300 of thetrim-rail 4000 mounts the solar panel(s) to a surface, such as the roofof a home or building, via connection to a footer (not shown). Since therail 4300 extends the entire length or width of at least one solar panelof a plurality of solar panels that are utilized in a solar panel array,so does the trim 4200. Rail 4300 can have an “I-beam” shape incross-section including a horizontal lower flange 4110 and a horizontalupper flange 4120, both connected by a vertical web 4140.

In FIG. 63, trim 4200 has a generally curved exterior surface 4040 thatextends downwardly and outwardly from the top of the trim-rail 4000 to alower vertical portion 4050 of the trim-rail 4000 and then downwardly toa lowest-most vertical portion 4070 of the rail 4300. Trim-rail 4000 isa hollow beam, including a hollow interior volume (hollow chamber) 4130.Trim-rail 4000 can be manufactured as an extruded product. The topportion of trim-rail 4000 is smoothly rounded over and it makes a smoothtransition with upper ledge 4010.

Thus, in FIG. 63, the trim 4200 can provide for anaesthetically-pleasing front surface for the trim-rail 4000 when thetrim-rail 4000 is used as the front-most rail in the hybrid solar panelmounting assembly of the present invention. Additionally, the trim-rail4000 can also assist in providing for a fire protection mechanism byfurther restricting the flow of air under the rail portion 4300, andthus under the photovoltaic module(s) that are mounted on the trim-rail4000. Lower vertical extension 4070 of rail 4300 aids in restrictingairflow underneath trim-rail 4000.

Thus, in FIG. 63, because the rail portion 4300 and the trim portion4200 of the trim-rail 4000 are a single, monolithic, integratedstructure, there is no need to mount a trim piece 4200 on a separaterail. The integrated structure of the trim-rail 4000 design provides forboth mounting a solar panel(s) to a surface by the rail 4300 andproviding a trim 4200 for the rail. Further yet, because the trim 4200and the rail 4300 are a single integrated structure, the trim 4200 ispart of the rigid structure of the trim-rail 4000, and thus, it is alsoa rigid structure itself. As such, the trim 4200 also directly supportsthe solar panel modules. In some embodiments, the wall thickness of trimportion 4200 can be the same as the wall thickness of rail portion 4300.

In FIG. 63, the rail 4300 includes a first track 4090 formed between theupper flange 4120 and the lower flange 4110. The bottom flange 4110 ofthe rail 4300 is the portion of the rail 4300 that is closest to themounting surface, e.g., the roof. As will be further discussed below,the track 4090 is able to receive within it mounting hardware, e.g., thehead of a bolt, that is used to mount the rail 4300 and thus trim-rail4000, on a footer (see FIGS. 65-66). The track 4090 is provided on oneside of the rail 4300 so that the footer may be mounted on the inside ofthe rail 4300. Opposite of the track 4090, on the other side of web4140, is a small hollow volume 4060. Lower flange 4110 contains a raisedoutside lip 4080 which is used to constrain the head of a bolt insertedinto track 4090. On the outer edge of upper flange 4120 is ahorizontally extending flange 4150 that extends along the longitudinallength of trim-rail 4000 and which serves to lock into a horizontalgroove (not shown) of an attached footer (see FIGS. 65-66).

In FIG. 63, a vertical wall 4100, i.e., vertical with respect to thesurface on which the trim-rail 4000 is mounted, is provided extendingupwards from the top flange 4120 of the rail 4300. Next, extendingperpendicularly, i.e., horizontally, from the vertical wall 4100 ishorizontal segment 4160 which intersects with vertical wall section 4020on the right-hand side of trim-rail 4000 (as viewed in FIG. 63).Vertical wall section 4020 extends downwardly from the top portion oftrim 4040. Extending horizontally from vertical section 4020 is a lowerledge (shelf) 4030 and an upper ledge (wing) 4010. The gap between theupper ledge 4010 and lower ledge 4030 defines a slot 10A into which asolar panel (or panels) is inserted. Lower ledge 4030 extendsconsiderably further outwards from vertical wall 4020 than upper ledge4010. An edge of a solar panel(s) that is mounted on trim-rail 4000 ispositioned between ledges 4030 and 4010. The bottom of the solar panelis supported on lower ledge 4030 and the top of the solar panel isdisposed under, and in engagement with, upper ledge 4010. Thus, the edgeof the solar panel is secured on trim-rail 4000 between lower ledge 4030and upper edge 4010 of trim section 4200.

In FIG. 63, trim-rail 4000 also includes a hollow chamber 4130 which isbounded on six sides by trim walls 4040 and 4050, vertical walls 4100and 4020, and bottom walls 4120 and 4160. Chamber 4130 receives splice5000 within it (see FIG. 64)

FIG. 64 illustrates an embodiment of splice 5000. Splice 5000 is used tosplice together two adjacent trim-rails 4000. A first end of the splice5000 is securely received within hollow chamber 4130 of a first adjacenttrim-rail 4000. A second end of the splice 5000 would be securelyreceived within a hollow chamber 4130 of a second adjacent trim-rail4000. Thus, the splice 5000 rigidly joins and aligns a first trim-rail4000 to a second adjacent trim-rail 4000 by firmly engaging withinrespective hollow chambers 4130 of adjacent trim-rails 4000.

In FIG. 64, the structure of splice 5000 has a geometry that iscomplementary and close-fitting to that of trim-rail 4000. Thus, thesplice 5000 has a trim-like portion 5100 that has a contour (profile)that is complementary to trim walls 4040, 4050 of trim section 4200.Thus, when splice 5000 is received within hollow chamber 4130 of atrim-rail 4000, the trim-like portion 5100 of splice 5000 generallyengages with the inside wall of trim 4200 of trim-rail 4000. Splice 5000has a hollow chamber 5200 and a connector 5300.

In FIG. 64 splice 5000 can be further secured within the adjacenttrim-rails 4000 by use of spring connector (interlock) 5300. As such,splice 5000 also has an internal structure that receives within it aportion of connector 5300 (see FIG. 4 for details of a similar connector300). Connector 5300 includes a pair of outwardly-bent spring straps,i.e., tabs, 5302, 5304 that are bent such that they are received withsplice 5000 and firmly engage into splice 5000 to secure connector 5300on splice 5000. At least portions of connector 5300 engage into bothtrim-rail 4000 and splice 5000 to electrically bond the trim-rail 4000to the splice 5000 and, hence, to an adjoining trim-rail 4000. Theseportions can be the respective straps 5302 and 5304.

FIG. 65 is a side view of the second embodiment of the trim-rail 4000mounted to a footer and a base, hereinafter referred to as a footerassembly 6000. FIG. 66 is a perspective view of the footer assembly.Trim-rail 4000 is removably mounted to footer assembly 6000 usingfastener 6050 with the fastener's head mounted in track 4090. Footermounting assembly 6000 includes a footer bracket 6010 which includes apair of vertical arms 6012 and 6014 which each include a plurality ofhorizontal ledges (teeth) 6022. For example, arm 6014 can include 8levels of ledges 6022. The grooves, i.e., slots, 6020 that are disposedin-between adjacent ledges 6022 engage and interlock with horizontallyprotruding flange 4150 on trim-rail 4000. The distance between adjacentledges 6022 can be, for example, ⅛″, which gives a total vertical heightadjustment capacity of 2″. In FIG. 66, an open vertical slot 6030 isdisposed in-between vertical arms 6012 and 6014. The shank of fastener(bolt) 6050 passes through slot 6030 and engages with a tri-drive nut6040 on the distal side of arms 6012, 6014. As will be further explainedlater in this specification, the tri-drive nut 6040 can be driven bythree different sized tools: (a) a large hexagonal socket wrench, e.g.,⅝″, (b) a smaller socket wrench, e.g., ½″, and (c) an Allen wrench tool.Use of three alternative drive tools gives the installer largeflexibility for selecting and using a single tool during installation.

Referring still to FIGS. 65 and 66, footer bracket 6010 further includesan integral horizontal flat leg 6016 which gives the footer 6010 an“L-shape.” Flat leg 6016 further includes an upwards-facing horizontallip 6018. Flat leg 6016 is disposed within, and is captured by, a pairof “I ”-shaped side clamps 7000, 7020. Clamps 7000, 7020 are compressedby a fastener, e.g., bolt, 7030, which provides a clamping and lockingforce onto horizontal leg 6016. The lower lip 7040 of side clamp 7020engages in a side groove 8030 that is horizontally-disposed along thelongitudinal length of base (track) 8000. Side clamp 7000 clamps ontobase 8000 through engagement in side groove 8032. Base 8000 is rigidlyfixed to a roof with a lag screw (not shown) that is disposed throughaperture 8010. A hollow chamber 8020 is disposed along the length ofbase 8000. Footer bracket 6010 further includes a lower leg 6060, thebottom of which rests on the upper surface 8002 of base 8000.

FIGS. 67 and 68 are perspective views of another embodiment of a solarpanel mounting bracket according to the present invention. Thisembodiment is generally the same as that illustrated in FIGS. 60-62,except that the overall length, L, is much greater in FIGS. 67 and 68than in FIGS. 60-62. In one example, the length L of micro-rail bracket9000 can be 17.5″ long, which is approximately equal to ½ of a maximumexpected rafter spacing, e.g., 24″, plus 5.5″, where the extra lengthequates to 2.5″-3.0″ of overhang at either end of the bracket 9000. Thewidth, W, of base track 8000 can be, for example, 1.5″ wide. In FIGS. 67and 68, the length, L, of micro-rail bracket 9000 is much longer thanthe width, W, of base track 8000. In some embodiments, the aspect ratio,L/W, of the bracket's length (L) to the width (W) of the base track canbe greater than 10. Alternatively, the aspect ratio L/W can be greaterthan 10 and less than 15. Alternatively, the aspect ratio L/W can equalapproximately 12˜(17.5/1.5). Alternatively, the length, L, can be lessthan or equal to (½ of the spacing between adjacent roof rafters)+5.5inches. Micro-rail bracket 9000 can include a pair of threadedfasteners, e.g., cap screws, 9400 and 9402, disposed at opposite ends ofbracket 9000. Micro-rail bracket 9000 can also include a pair of bondingpins 9300, 9302 disposed at opposite ends of bracket 9000 and located onthe clamping side of bracket 9000.

Referring to FIG. 67, micro-rail bracket 9000 includes an upper clampingportion 9200 and a lower base supporting member 9100. Disposed withinbase supporting member 9100 is a series of three rectangular-shapedapertures 9602, 9604, and 9606, located at the east end, middle, andwest end of the bracket 9000, respectively. These apertures 9602, 9604,and 9606 are sized to accept a single vertical structural support tower(stanchion) 9500 of the height adjustable mounting assembly, whichengages with the helical drive and which is attached to base track 8000.In between each aperture 9602, 9604, 9606 is a solid bridge segment9802, 9804, respectively, which separates each aperture. Depending onwhere the micro-rail bracket 9000 is positioned with respect to theunderlying roof rafters (Central location, West end, or East end), thesupport tower 9500 can be variably-discretely placed within one of thethree apertures 9602, 9604, and 9606. For example, FIG. 68 shows thesupport tower 9500 being located in aperture 9606 at the West end ofmicro-rail bracket 9000. In this way, the support tower 9500 isvariably-discretely positionable with respect to the longitudinal axisof bracket 9000, i.e., in one of three fixed positions. In general, aplurality of discrete locations can be used to provide variable-discretepositioning of the support tower 9500 in bracket 9000. The number ofdiscrete locations can be, for example, 1, 2, 3, 4, or 5, depending onthe length of bracket 9000. Bracket 9000 further includes threetool-access holes 9702, 9704, and 9706 that are located directly aboveeach of the three rectangular-shaped apertures 9602, 9604, and 9606,respectively, for providing easy access to adjust the helical verticaldrive mechanism (and, thus, adjust the PV module height off the deck).In this way, the base track 8000 is not confined to a single position onbracket 9000, but, rather, can be variably positioned at three differentdiscrete locations along the length of bracket 9000 in order toco-locate the position of the base track 8000 with an underlying rafteron the roof structure.

In another embodiment, with reference to FIG. 69, bridge segments 9802and 9804 are eliminated and replaced with open space. In thisembodiment, then, apertures 9602, 9604 and 9606 are merged into onesingle continuous open slot 9900, as shown in FIG. 69, within whichtower 9500 can be continuously variably-positioned in the East-Westdirection. As such, as can be seen, the tower is movable within the slotand along a length of the slot, where the length of the slot is at leasttwo times the length of the tower. In addition, discrete tool-accessholes 9702, 9704, 9706 are replaced by a single, continuous access slot9910 that runs in the East-West direction.

Further Rail-Less or Non-Rail-Based System Components

FIGS. 70-71 illustrate an apparatus for mounting photovoltaic modulesaccording to another embodiment of the present invention. A floatingclamp assembly 10000 for holding solar panels together is disclosed,which can also be a bracket of a rail-less or non-rail-based system. Thefloating clamp assembly 10000 basically includes the same structure ofan upper bracket 10100 and a lower bracket 10200 as per the upperbracket 3100 and lower bracket 3200 of the bracket of the embodiment ofFIGS. 60-62, with the exceptions that, as can be seen, the lower bracket10200 does not include the lower structure of the lower bracket 3200 anddoes not includes apertures for a stanchion and a tool.

Thus, as can be seen, the assembly 10000 includes an upper bracket 10100and a lower bracket 10200 (which together form a mounting bracket formounting solar panels). Upper bracket 10100 includes a first arm 10110,a second arm 10120, a base 10130, and a bottom wall 10140 that has alower end that engages with a slot 10234 that is disposed within, andlays across the width of, lower bracket 10200. Lower bracket 10200includes a first arm 10210 and a second arm 10220.

First and second clamping bolts 10300, 10302 clamp the upper bracket10100 down to lower bracket 10200 when one or more solar panels areinstalled in each of slots 10A, 10B, which are defined between therespective arms of the upper and lower brackets. Stop bar 10222 runssideways across the width of lower bracket 10200 and serves as a stop toabut against, and align, the solar panel(s) when installed in slot 10A.Bonding pins 10230 are disposed in respective holes located in recessedchannel 10232 in lower bracket 10200. Bonding pins 10230 serves topierce the anodized aluminum coating on the solar panel(s) andelectrically interconnect (ground) the solar panel(s) to the lowerbracket 10200 of assembly 10000.

As can be seen in FIG. 70, when solar panels A and B are respectivelydisposed in slots 10A and 10B, solar panel B is loosely captured withinslot 10B when the clamping bolts 10300, 10302 are tightened. The gapbetween solar panel B and the first arm 10110 of upper bracket 10100 isapproximately 1 mm.

The assembly 10000 is referred to as a “floating splice” since theassembly is supported above the surface on which the solar panels areotherwise mounted, and thus, the splice only contacts the solar panelsand does not contact the surface.

In an installation, slot 10A is a South-facing side of the assembly andslot 10B is a North-facing side of the assembly. The bonding pins makean electrical connection to the frames of clamped solar panels with asteady-state electrical resistance less than or equal to 0.010 Ohms, asmeasured per the Bonding Path Resistance Test specification described inUL 2703.

In an embodiment, the upper bracket and the lower bracket are asingle-piece, continuous, integral object.

Multi-Drive Nut

FIGS. 72-74 illustrate a first embodiment of a multi-drive nut forattaching to a fastener, as discussed previously. A multi-drive bolt orscrew includes a head and a threaded shank. The head is a multi-drivenut 11000 with a body, internal threads, a proximal end 11200 and adistal end 11202, and three concentric drive mechanisms for driving thenut. The three concentric drive mechanisms are disposed on an outside ofthe body and include a first external drive 11102 and a second externaldrive 11104. Thus, the multi-drive nut 11000 can be driven, i.e.,rotated, by two differently sized, externally applied tools. Forexample, a large hexagonal socket wrench, e.g., ⅝″, can be used withfirst external drive 11102 and a smaller hexagonal socket wrench, e.g.,½″, can be used with second external drive 11104. The larger diameterexternal drive 11102 is disposed near the proximal end 11200 of the nutand the smaller diameter external drive 11104 is disposed near thedistal end 11202 of the nut.

Further, the multi-drive nut includes a third drive mechanism, which isdisposed inside the body and is an internal drive 11106, which may bedriven by, for example, an Allen wrench tool. The internal drive 11106is disposed at the distal end 11202 of the nut. Optionally, the hollowshaft of the internal drive 11106 may extend along the entire length ofthe multi-drive nut, with openings at both the proximal and distal ends.

The multi-drive nut also includes a flanged base 11108 which includes aplurality of angled, radial serrations that are disposed around thecircumference of the flanged base. A threaded aperture 11101 is includedat the proximal end 11200 for receiving a threaded shank.

FIGS. 75-76 illustrate a second embodiment of a multi-drive nut forattaching to a fastener, as discussed previously. The head is also amulti-drive nut 12000 with a body and including internal threads, aproximal end 12200 and a distal end 12202, and five concentric drivemechanisms for driving the nut. The five concentric drive mechanismsinclude a first external drive 12102, a second external drive 12104, anda third external drive 12106. Thus, the multi-drive nut 11000 can bedriven, i.e., rotated, by three differently sized, externally appliedtools. The largest diameter external drive 12102 is disposed near theproximal end 12200 of the nut and the smallest diameter external drive12106 is disposed near the distal end 12202 of the nut, and the drive12104 that is sized between the largest and smallest drives is disposedbetween the largest 12102 and smallest 12106 drives.

Further, the multi-drive nut includes fourth and fifth drive mechanisms,which are internal drives 12108 and 12110, which may be driven by, forexample, differently sized Allen wrench tools (hex socket). The internaldrive 12110 is disposed at the distal end 12202 of the nut and theinternal drive 12108 is disposed intermediate the distal end 12202 andthe proximal end 12200. Internal drive 12110 is larger than internaldrive 12108. As such, internal drive 12110 has a larger radius from thecenterline of the nut than does internal drive 12108.

The multi-drive nut 12000 also includes a flanged base 12112 which alsocan include a plurality of angled, radial serrations that are disposedaround the circumference of the flanged base. A threaded aperture 12101is included at the proximal end 12200 for receiving a threaded shank.

In other embodiments, the multi-drive nut can be an un-threaded cap endof a multi-drive bolt or a multi-drive screw.

Whereas the external drives are disclosed as being hexagonal in shape,they may also be a square or triangular drive. The internal drives maybe a hex drive, or a Torx™ drive, a star drive, a square drive, or atriangular drive, or combinations thereof.

Use of these alternative drive tools gives the installer largeflexibility for selecting and using a single tool during installation.The disclosed number of external drives and internal drives may be usedin any combination, separately, or in any number.

Further Rail-Less or Non-Rail-Based System Components

FIG. 77 shows an exploded perspective view of another embodiment of afloating splice assembly according to the present invention. Thisembodiment is similar to what is shown previously in FIGS. 70 and 71,and whereas otherwise noted, uses the same reference numbers for thesame parts. In FIG. 77, the lower bracket 10200 further includes asymmetric pair of stiffening ribs (wings) 10400 and 10410 and adjoiningpair of vertical walls, disposed underneath the horizontal arms 10210and 10220, respectively. These stiffening ribs serve to stiffen thelower bracket and to increase its bending strength along the long axis.A slot 10500 is defined between the adjoining pair of vertical walls.

Floating clamp assembly 10000 further includes three slots 10700 forreceiving fastening cap bolts 10300, 10302, and 10304. A pair of bondingpins 10600 can be seen, which are press-fit into respective holes. Thelength of floating splice 10000 can be about 9 inches, in someembodiments. Upper bracket 10100 is a “clamp and capture/catch” type ofattachment bracket, where 1 or 2 solar panels are clamped on side 10Aand where 1 or 2 solar panels are captured (catched) on the oppositeside 10B.

Trim-Rail with a Tilted Ledge

FIG. 78 is a perspective view of another embodiment of a trim-railaccording to the principles of the present invention. The trim-rail ofthis embodiment has a tilted ledge. Trim-rail 13000, which may be anextrusion, can have any length L and is similar to the trim-rail of theembodiment of FIG. 63. The primary difference is shown in FIG. 78, wherethe trim-rail has a tilted portion 13008 that is tilted upwards at anangle, θ, with respect to horizontal, i.e., a horizontal plane. The tiltangle, θ, which can be particularly seen in FIG. 79, can range from 10to 30 degrees and, thus, can be equal to 20 degrees. Attached to thetitled portion 13008 is a distal portion 13009 which is horizontal. Thetilted spring support ledge 13006 includes, then, a combination of thetilted portion 13008 and the horizontal distal portion 13009. The tiltedspring ledge 13006, then, in an embodiment, extends outwardly from aninner (proximal) horizontal portion 13007, which has a thickercross-section than the tilted spring ledge 13006. The thickness of theproximal support portion 13007 can be at least 3 times greater than thethickness of the tilted spring support ledge 13006. If proximal portion13007 is not used, the tilted spring support ledge 13006 would extendfrom the vertical wall section 4020 of the trim-rail. The remainder oftrim-rail 13000 is similar to the trim-rail shown in FIG. 63 and for thesame components, the same reference numbers are used in both Figures.

FIG. 79 is a right end view of the trim-rail with the tilted springledge. The tilted spring ledge 13006 forms a cantilevered beam that islong and thin. It has a thickness (t) and width (W) where the aspectratio of W/t is greater than or equal to 10. In another embodiment, theaspect ratio of W/t is greater than or equal to 15. The cantilevereddesign of the tilted spring support ledge 13006 means that the ledgeacts as a cantilevered, elastic beam that deflects vertically whenloaded by a photovoltaic module (not shown) when installed/mounted inslot 10A. Tilted spring ledge 13006 provides an elastic, spring-likeaction, which generates a reaction (supporting) force that reactselastically in a vertical direction, pushing up against the underside ofthe photovoltaic module when the module is inserted and rotated downagainst the tilted spring ledge 13006, thereby reducing any verticalclearance gap between the photovoltaic module and the upper ledge/wing13012 of the upper bracket 13014 of the trim-rail to essentially zero.

The proximal horizontal portion 13007, if used, is shorter and thicker,hence it does not deflect as much as the thinner and longer tiltedspring ledge 13006.

FIG. 80 is a front view of the trim-rail 13000. FIG. 81 is a rear viewof the trim-rail 13000. FIG. 82 is a top view of the trim-rail 13000.FIG. 83 is a bottom view of the trim-rail 13000.

FIGS. 84A and 84B are right end views of an embodiment of a solar panelmounting assembly for mounting a photovoltaic module 15000 to trim-rail13000 with the tilted spring support ledge 13006. FIG. 84A showstrim-rail 13000 with upper wing 13012, tilted spring support ledge13006, proximal horizontal portion 13007, footer assembly 14000,tri-drive nut 14100, fastener (t-bolt) 14150, side clamp 14200, and basetrack 14300. During installation, photovoltaic module 15000 is insertedat an angle (approximately 20-30 degrees) into the open slot 10A definedby the tilted spring support ledge 13006 and the proximal horizontalportion 13007 on a lower side and the upper wing 13012 on an upper side.Slot 10A is further defined by the integral vertical wall section 4020on a middle portion of the slot 10A. Upper wing 13012 clamps onto one ormore photovoltaic modules 15000.

Once the photovoltaic module 15000 has been inserted into slot 10A andmakes contact with the tilted spring support ledge 13006, thephotovoltaic module 15000 is rotated back downwards to a horizontalposition, thereby deflecting the spring-like, cantilevered portion 13008of tilted spring support ledge 13006 back down to a substantiallyhorizontal position (see FIG. 84B). However, as can be seen in FIG. 84B,when deflected back down, the tilted portion 13008 does not completelybecome horizontal (flatten out). Rather, it remains partially tilted upat a smaller angle, e.g., less than 5 degrees, which reduces any gapbetween the upper portion of photovoltaic module 15000 and the upperwing 13012 to essentially zero by action of the tilted spring supportledge 13006 pushing up on the bottom portion of photovoltaic module15000. By the action of the tilted spring support ledge 13006 pushing upon the photovoltaic module 15000, when properly assembled, no rattlingof the assembly occurs when it is subjected to vibration, e.g., shaken.Thus, tilted spring support ledge 13006 acts as an “anti-rattle”feature.

The foregoing disclosure has been set forth merely to illustrate theinvention and is not intended to be limiting. Since modifications of thedisclosed embodiments incorporating the spirit and substance of theinvention may occur to persons skilled in the art, the invention shouldbe construed to include everything within the scope of the appendedclaims and equivalents thereof.

What is claimed is:
 1. A trim-rail for use in a solar panel mountingassembly, comprising: a first vertical wall; a horizontal wallintersecting with the first vertical wall; a second vertical wallintersecting with the horizontal wall and extending downwardly from thehorizontal wall, the second vertical wall having a free end thatterminates a distance apart from the horizontal wall, and the secondvertical wall being spaced apart from the first vertical wall such thata gap exists therebetween, the gap sized to receive a portion of afooter; a proximal support portion extending horizontally from the freeend of the second vertical wall in a direction away from the gap; and atilted spring support ledge integrally joined to, and cantilevered from,the proximal support portion, wherein a photovoltaic module iselastically supportable on the tilted spring support ledge when thephotovoltaic module is installed on the tilted spring support ledge. 2.The trim-rail of claim 1, wherein the tilted spring support ledge istilted at an angle ranging from 10-30 degrees to a horizontal plane whenthe photovoltaic module is not mounted on the tilted spring supportledge.
 3. The trim-rail of claim 1, wherein the tilted spring supportledge is tilted at an angle of approximately 20 degrees to a horizontalplane when the photovoltaic module is not mounted on the tilted springsupport ledge.
 4. The trim-rail of claim 1, wherein the tilted springsupport ledge includes a tilted portion and a horizontal distal portion.5. The trim-rail of claim 1, wherein a thickness of the proximal supportportion is at least 3 times greater than a thickness of the tiltedspring support ledge.
 6. The trim-rail of claim 1, wherein the tiltedspring support ledge has a width (W) and a thickness (t) sufficient toprovide an elastic, spring-like force that pushes upward on aphotovoltaic module when the photovoltaic module is installed on thetilted spring support ledge so as to minimize a gap between an upperbracket of the trim-rail and the photovoltaic module.
 7. The trim-railof claim 6, wherein a ratio of the width to the thickness (W/t) isgreater than or equal to
 10. 8. The trim-rail of claim 6, wherein aratio of the width to the thickness (W/t) is greater than or equal to15.
 9. A solar panel mounting assembly, comprising: a trim-railincluding: a first vertical wall, a horizontal wall intersecting withthe first vertical wall, a second vertical wall intersecting with thehorizontal wall and extending downwardly from the horizontal wall, thesecond vertical wall having a free end that terminates a distance apartfrom the horizontal wall, and the second vertical wall being spacedapart from the first vertical wall such that a gap exists therebetween,the gap sized to receive a portion of a footer, a proximal supportportion extending horizontally from the free end of the second verticalwall in a direction away from the gap, and a tilted spring support ledgeintegrally joined to, and cantilevered from, the proximal supportportion, and a slot defined by the tilted spring support ledge on alower side of the slot, the second vertical wall on a middle portion ofthe slot, and a wing on an upper side of the slot.
 10. The solar panelmounting assembly of claim 9, wherein the tilted spring support ledge istilted at an angle ranging from 10-30 degrees to a horizontal plane whenthe photovoltaic module is not supported on the tilted spring supportledge.
 11. The solar panel mounting assembly of claim 9, wherein thetilted spring support ledge is tilted at an angle of approximately 20degrees to a horizontal plane when the photovoltaic module is notsupported on the tilted spring support ledge.
 12. The solar panelmounting assembly of claim 9, wherein the tilted spring support ledgeincludes a tilted portion and a horizontal distal portion.
 13. The solarpanel mounting assembly of claim 9, further comprising a photovoltaicmodule configured to be mounted in the slot upon installation of thesolar panel mounting assembly.
 14. The solar panel mounting assembly ofclaim 13, wherein the tilted spring support ledge is deflected when thephotovoltaic module is installed in the slot, and wherein the deflectedtilted spring support ledge provides a vertical force that pushes upwardon the installed photovoltaic module so as to minimize a gap between thewing and the photovoltaic module.
 15. The solar panel mounting assemblyof claim 9, wherein the tilted spring support ledge has a width (W) anda thickness (t) and wherein a ratio of the width to the thickness (W/t)is greater than or equal to
 10. 16. The solar panel mounting assembly ofclaim 9, wherein the tilted spring support ledge has a width (W) and athickness (t) and wherein a ratio of the width to the thickness (W/t) isgreater than or equal to
 15. 17. The solar panel mounting assembly ofclaim 9, further comprising: a footer assembly including the footer, thefooter being configured to be clamped in the gap by a tri-drive nut wheninstalled; and a base track configured to be clamped to the footerassembly when installed.
 18. The solar panel mounting assembly of claim17, further comprising a photovoltaic module configured to be is mountedin the slot upon installation of the solar panel mounting assembly. 19.A method of mounting a photovoltaic module in a trim-rail, the trim-railincluding: a vertical wall intersecting with, and extending downwardlyfrom, a horizontal wall, the vertical wall having a free end terminatinga distance apart from the horizontal wall a proximal support portionextending from, and transversely to, the free end of the vertical wall,a tilted spring support ledge integrally joined to, and cantileveredfrom, the proximal support portion, a thickness of the proximal supportportion being greater than a thickness of the tilted spring supportledge, and a slot defined by the tilted spring support ledge on a lowerside of the slot, the vertical wall on a middle portion of the slot, anda wing on an upper side of the slot; the method comprising steps of:inserting the photovoltaic module into the slot at an angle with respectto a horizontal plane; and rotating the photovoltaic module back to thehorizontal plane and deflecting the tilted spring support ledge by thephotovoltaic module, wherein the deflecting generates a vertical upwardforce on the photovoltaic module by the tilted spring support ledge soas to minimize a gap between the wing and the photovoltaic module.